Trane UX2B060A9362A, UX2D120A9602A, DX2B060A9362A, DX2B080A9422A, DX2C100A9482A Installer's Manual

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Page 1

IIIIII IIIIIIIIIIIIII IIIIIIII

1 8- CD1 9 D8- 1 5

Upflow / Horizontal & Downflow / Horizontal,

Gas-Fired, Direct Vent, 2-Stage Condensing

Furnaces with Variable Speed Inducer

*UX2B060A9362A *UX2B080A9422A *UX2C100A9482A *UX2D120A9602A *DX2B060A9362A *DX2B080A9422A *DX2C100A9482A *DX2D120A9602A

*__Firstlettermay be"A" or "T"

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

IMPORTANT -- This Document is customer property and is to remain with this unit.

Please return to service information pack upon completion of work.

*UX2 *DX2

DOWNFLOW

A!R

A/R

FLOW

UPFLOW

AIR

FLOW

UPFLOW/HORIZONTAL LEFT

DOWNFLOW/HORIZONTAL RIGHT

/ _

FLOW

i °

A341624P03

Page 2

Installer's Guide

SAFETY SECTION

The following safety practices and precautions must be followed during the installation, servicing, and operation of

this furnace.

1. Use only with the type of gas approved for this furnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and position as specified in "Location and Clearances" (page 3), of these

instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified in "Air for Combustion and

Ventilation" (pages 7-8), of these instructions.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as

specified in the "Venting" section (pages 13-23), of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as

specified in "Gas Piping" (page 31), of these instructions.

6. Always install the furnace to operate within the furnace's intended temperature-rise range with a duct system

which has an external static pressure within the allow- able range, as specified on the unit rating plate. Airflow

with temperature rise for cfm versus static is shown in the Service Facts accompanying this furnace.

7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space

containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and

terminating outside the space containing the furnace.

8. A gas-fired furnace for installation in a residential garage must be installed as specified in "Location and

Clearances" section (page 3), of these instructions.

9. The furnace may be used for temporary heating of buildings or structures under construction only when the

following conditions have been met: a. The furnace venting system must be complete and

installed per manufacturer's instructions.

b. The furnace is controlled only by a room thermostat

(no field jumpers).

c. The furnace return air duct must be complete and

sealed to the furnace and clean air filters are in place.

d. The furnace input rate and temperature rise must be

verified to be within nameplate marking.

e. 100% of the furnace combustion air requirement must

come from outside the structure.

f. The furnace return air temperature range is between

55 and 80 degrees Fahrenheit.

g. Clean the furnace, duct work, and components upon

substantial completion of the construction process, and verify furnace operating conditions including

ignition, input rate, temperature rise and venting, according to the manufacturer's instructions.

10. This product must be gas piped by a Licensed Plumber or Gas Fitter in the Commonwealth of Massachusetts.

CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each

appliance connected to the venting system being placed into operation could result in carbon monoxide

poisoning or death.

The following steps shall be followed for each appliance

connected to the venting system being placed into operation, while all other appliances connected to the

venting system are not in operation:

1. Seal any unused openings in the venting system.

Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 or the CAN/CGA B149 Installation Codes and these instructions. Determine

that there is no blockage or restriction, leakage,

corrosion and other deficiencies which could cause an unsafe condition.

As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are

located and other deficiencies which could cause an unsafe condition.

4. Close fireplace dampers.

Turn on clothes dryers and any appliance not

connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate

a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

If improper venting is observed during any of the above

tests, the venting system must be corrected in

accordance with the National Fuel Gas Code, ANSI Z221.1/NFPA 54 and/or CAN/CGA B149

Installation Codes.

After it has been determined that each appliance connected to the venting system properly vents where

tested as outlined above, return doors, windows,

exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

Safety signal words are used to designate a degree or level of seriousness associated with a particular hazard. The

signal words for safety markings are DANGER, WARNING, and CAUTION.

a. DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury. This signal word is limited to the most extreme situations.

b. WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

c. CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

To prevent shortening its service life, the furnace should not be used as a "Construction Heater" during the finishing

phases of construction until the requirements listed in item 9, a-g of the safety section of this publication have been

met. Condensate in the presence of chlorides and fluo- rides from paint, varnish, stains, adhesives, cleaning

compounds, and cement create a corrosive condition which may cause rapid deterioration of the heat exchanger.

FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in

serious injury, death or property damage.

Improper servicing could result in dangerous operation,

serious injury, death, or property damage.

Page 3

Installer's Guide

GENERAL

The manufacturer assumes no responsibility for equipment installed in violation of any code or regulation.

It is recommended that Manual J of the Air Conditioning Contractors Association (ACCA) or A.R.I. 230 be followed in estimating heating requirements. When estimating heating requirements for installation at Altitudes above 2000 ft., remember the gas input must be reduced (See GAS INPUT

ADJUSTMENT).

Material in this shipment has been inspected at the factory and released to the transportation agency without known damage. Inspect exterior of carton for evidence of rough handling in shipment. Unpack carefully after moving equipment to approximate location. If damage to contents is found, report the damage immediately to the delivering agency.

Codes and local utility requirements governing the installa- tion of gas fired equipment, wiring, plumbing, and flue connections must be adhered to. In the absence of local codes,

the installation must conform with latest edition of the National Fuel Gas Code ANSI Z223.1 • National Installation

Code, CAN/CGA B149.1. The latest code may be obtained from the American Gas Association Laboratories, 400 N. Capitol St. NW, Washington D.C. 20001. 1-800-699-9277 or

www.aga.org These furnaces have been classified as CATEGORY IV

furnaces in accordance with latest edition of ANSI Z21.47 standards ° CAN/CGA 2.3. Category IV furnaces operate

with positive vent static pressure and with a flue loss less than 17 percent. These conditions require special venting systems, which must be gas tight and water tight. These Category IV Direct Vent furnaces are approved for installa- tion in Manufactured/Mobile housing when used with

BAYMFGH001A.

LOCATION AND CLEARANCES

The location of the furnace is normally selected by the architect, the builder, or the installer. However, before the furnace is moved into place, be sure to consider the following requirements:

1. Is the location selected as near the chimney or vent and as centralized for heat distribution as practical?

2. Do all clearances between the furnace and enclosure equal or exceed the minimums stated in Clearance Table on the Outline Drawings.

3. Is there sufficient space for servicing the furnace and other equipment? A minimum of 24 inches front accessi-

bility to the furnace must be provided. Any access door

or panel must permit removal of the largest component.

4. Are there at least 3 inches of clearance between the furnace combustion air openings in the front panel and any closed panel or door provided?

5. Are the ventilation and combustion air openings large enough and will they remain unobstructed? If outside air is used, are the openings set above the highest snow

accumulation level? (See the Air for Combustion and

Ventilation section.)

6. Allow sufficient height in supply plenum above the furnace to provide for cooling coil installation, if the cooling coil is not installed at the time of this furnace

installation.

7. A furnace shall be installed so electrical components are protected from water.

8. If the furnace is installed in a residential garage, it must be installed so that the burners, and the ignition

18-CD19D8-15 3

Contents

Installation Instructions

General Location and Clearances

Outline Drawings Upflow Installation

Downflow Installations Air For Combustion and Ventilation

Duct Connections Return Air Filters General Venting Venting Materials

Vent Tables Horizontal Venting Through Wall

Venting Through the Roof Venting Routed Through a Masonry Chimney

Downward Venting Condensate Drain Instructions

Field Wiring Diagrams Electrical Connections

Gas Piping Combustion and Input Check High Altitude Derate

Start-up and Adjustment

Preliminary Inspections Lighting Instructions

Sequence of Operation Control and Safety Switch Adjustments

Abnormal Conditions

IFC Error Flash Codes

Fault Code Recovery

source are located not less than 18 inches above the floor and the furnace must be located or protected to avoid

physical damage from vehicles.

IMPORTANT:

The furnace must be installed level The only allowable variation

would be slightly to the left and/or forward in upflow installations or slightly toward the front in horizontal installations. This is necessary for proper condensate drainage.

Do not install the furnace in a corrosive or contaminated atmosphere. Failure to follow this warning could result in

early equipment failure.

Do not install the furnace directly on carpeting, tile or other combustible material other than wood flooring. For vertical downflow application, subbase (BAYBASE205) must be used between the furnace and combustible flooring. When

the downflow furnace is installed vertically with a cased

coil, a subbase is not required.

Page 4

ED oo

DIM"C"

5/8" J

-,-- 5/8" 4- I/ilJ

OUTLET t°_

AIR /._

OUTSIDEAIR

7/8" HOLE_

ELECTRICALLY.... _ ,

SUPPLY ,_._ .... _1

1/78" x 7/8"_

SLOT KNOCKOUT

CONDENSATE DRAIN

(HORIZONTAL)

I-I/8" KNOCKOUT-

CONDENSATE DRAIN

I-5/16"--=-

,l-m..

01_0

23-3/4"

-i

DIM "D"

3/4,,_-

3/4" --_

--,_ 28- I /2" -_,.

INLET I • I

AIR "

I_ 24- I/32" _-J L 3-7/32"

DIM "B"

_---r_2"FLUE CONNECT

SEE NOTES I & 2

"E"

"'--4-1/16"

*UX2 UPFLOW / HORIZONTAL OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

',1-3-15/16"

"--2-1/16"

-¢1-1/2" GAS

SUPPLY

"-2-1/8"

__T

I -7/8 22-

--__20-1/4"

5 "

18-

2 ii

[

;0-5/8"

/4" I

IZONTAL APPLICATION

IS SIDE ONLY)

I/2"_

40"

DIM "A" ---,'-

-,- I/2"

Model

DIM "A" DIM "B" DIM "C" DIM "D" DIM "E" DIM "F"

(See Note 1 & 2)

*UX2B060A9362A

17-1/2" 2-1/4" 16-1/4" 16" 7-1/2" 2"

*UX2B080A9422A

*UX2C100A9482A 21" 2-1/2" 19-3/4" 19-1/2" 9" 3" *UX2D120A9602A 24-1/2" 2-15/16" 23-1/4" 23" 10" 3"

* Prefix May Be "A" or "T" Notes:

1. *UX2D120A9602A Requires 3" Diameter Vent Pipe. *UX2C100A9482A Requires 2-1/2" or 3" Diameter Vent Pipe.

2. Diameter of Vent Pipe may be limited to 2-1/2" or 3" on some models at different altitudes. Refer to the Vent Length Table for proper application.

7/8" KNOCKOUT ELECTRICAL SUPPLY

(ALTERNATE)

-_1-1/2" KNOCKOUT GAS SUPPLY

(ALTERNATE)

I/8" KNOCKOUT

DRAIN

(ALTERNATE)

MINIMUMCLEARANCETO

COMBUSTIBLE MATERIALS

SIDES O IN. REAR 0 IN. FRONT 3 IN, TOP I IN. FLUE 0 IN.

HORIZONTAL(FLUE BSCHARGEON THE LEFTI

ALCOVE

SIDES

RIGHT O IN

LEFT O IN REAR 6 IN FRONT 18 IN TOP I IN, FLUE 0 IN,

CLOSET

SIDES

RIGHT I IN

LEFT I IN REAR 3 IN FRONT 3 IN TOP I IN

FLUE 0 IN,

From Dwg. 21C341884 Rev. 1

ltl

Ill

I I

Ill

n_ iI

Page 5

qo 0 oo

t_n

....... 19 5'8 .......

......._2" F u

, CON'\ECT

SEE IOTE J

DIM "D"

3/4

o_ a,,6,_.... j i 7 _,,4"

*DX2 DOWNFLOW / HORIZONTAL OUTLINE DRAWING

(ALL DIMENSIONS ARE IN INCHES)

From Dwg. 21C341885 Rev. 1

,; llOlR z.N '. t,,_l C,\I ON

',, IS _i i . I

2-i ,'8 ........."-

' 0 "

DIM "A" ,.-.-

23/i6"

Model

DIM "A" DIM "B" DIM "C" DIM "D"

(See Note 1)

*DX2BO60A9362A

17-1/2" 2-1/4" 16-1/4" 16"

*DX2BO80A9422A

*DX2C100A9482A 21" 2-1/2" 19-3/4" 19-1/2" *DX2D120A9602A 24-1/2" 2-15/16" 23-1/4" 23"

Prefix May Be "A" or "T" Notes:

1. Diameter of Vent Pipe may be limited to 2-1/2" or 3" on some models at different altitudes. Refer to the Vent Length Table for proper application.

/ _,S,'8' L C R CAL

/ (ONNIC ON AI Ei!'NA I

/ / ,_'S'/6' i( IRICA

/ CONN ?liON ,*,L ERNAIE)

/ NOC Oi

kc,,,INE_T k.

i ?5"

0 /z"

"--- ¢ ......s

,,,Jr ,E DA

--w u T

If ,,,,J v ,

MINIMUM CLEARANCE TO COMBUSTIBLE MATERIALS

DOWNFLOW

SIDES 0 REAR 0 I ROi' I 3 ', O[ N i I b E 0 N

HORIZONTAL (FLUE DISCHARGE ON THE LEFT)

ALCOVE

SIDES

RI iT 0 \

REAR 6 _N iRON[ 18 N

-OR N FlU 0 \

CLOSET

SIDES

[EFT ;N REAR _N FRONT _N lOP iN FI U_ i N

Itl

Iit

m m

Page 6

Installer's Guide

UPFLOW INSTALLATION

Standoffs and screws (See Figure 1) are included with the cased coils for attachment to the furnace. There are clear-

ance alignment holes near the bottom of the coil wrapper. Drill screws are used to engage the furnace top flanges. The standoff is inserted into the cabinet alignment hole. The drill screws are inserted through the standoffs then screwed into the furnace flange. The coil is always placed downstream of

the furnace airflow.

STANDOFFS (4) DRILL SCREWS (4)

FOR VERTICAL

- SCREWS (BOTH BIDES)

STANDOFFS

(BOTH SIDES)

DOWNFLOW INSTALLATIONS

(_ CABINET SIDE CABINET SIDE

SUB-BASE SUB-BASE

FLANGE FLANGE

(BENT UP) (BENT UP)

DUCT

Do not install the furnace directly on carpeting, tile or other combustible material other than wood flooring. For vertical downflow application, subbase (BAYBASE205)

must be used between the furnace and combustible flooring. When the downflow furnace is installed vertically

with a cased coil, a subbase is not required.

Required floor opening: (DOWNFLOW)

See Figure 3 and Table I

TABLE 1

CABINET RETURN FLOOROPENING PLENUM OPENING

WIDTH DUCT WIDTH "A.... B.... C.... D"

14-1/2" 13-1/4" 13-5/8" 20-1/8" 12-5/8" 19-3/8" 17-1/2" 16-1/4" 16-5/8" 20-1/8" 15-5/8" 19-3/8"

21" 19-3/4" 20-1/8" 20-1/8" 19-1/8" 19-3/8"

24-1/2" 23-1/4" 23-5/8" 20-1/8" 22-5/8" 19-3/8"

HORIZONTAL INSTALLATION

The coil and furnace must be fully supported when used in the horizontal position. It is always recommended that an auxiliary drain pan be installed under a horizontally in- stalled evaporator coil or 90% gas furnace. Connect the auxiliary drain line to a separate drain line (no trap is

needed in this line). Three brackets (with screws) are included with downflow

furnaces for installation to stabilize and secure the furnace and TXC cased coil in the horizontal position. See Fig-

ure 4.

CASED COIL CONNECTION

BRACKET FOR DOWNFLOW

FURNACE IN HORIZONTAL

DOWNFLOW ONLY

IMPORTANT: The 2/4TXC cased coil must be placed downstream of the

furnace. In horizontal installations, the apex of the coil may point either toward or away from the furnace. See

the 2/4TXC coil Installer's Guide for more details.

The cased coil is secured to the furnace and both the furnace and the cased coil must be properly supported. The brackets

mount using the rear screws on the coil case and use the screws provided to secure the bracket to the furnace. The remaining bracket is placed as close to center as possible (horizontally) between the coil case front and the furnace

bottom channel (for downflow/horizontal furnace). Use four of the screws provided to secure the bracket. The upflow furnace,

converted to horizontal, aligns and attaches the TXC coil as in Figure 1. However, the coil requires additional support.

The furnace may be installed in an attic or crawl space in the horizontal position by placing the furnace on the left side (as viewed from the front in the vertical position). The horizontal furnace installation in an attic should be on a service plat- form large enough to allow for proper clearances on all sides and service access to the front of the furnace (See Figure 5 & Clearance Tables, pages 4-5). Line contact is only permis- sible between lines formed by intersections of the top and two sides of the furnace casing and building joists, studs, or framing.

The furnace may be placed horizontally in a crawl space on a pad or other noncombustible material which will raise the unit for sufficient protection from moisture.

UPFLOW/ I

HORIZONTAL I

SHOWN WITH DIRECT VENT

18-CD19D8-15

Page 7

Installer's Guide

[--

50 CU. FT. OR MORE

UNCONFINED

The furnace must be supported at both ends and the middle when installed horizontally. The furnace must

also be elevated approximately 4-6 inches to allow

clearance for the condensate drain to exit the cabinet in

the horizontal position.

The horizontal furnace may also be suspended from the joists using 3/8" all-thread rods with pieces of angle iron under-

neath the furnace to form a hanging rack at both ends and the midpoint. The rods need to be of sufficient length to

allow for proper clearances from combustible materials. The angle iron needs to be at least 32" in length to allow for

access to service panels.

AIR FOR COMBUSTION AND VENTILATION

If these furnaces are installed in a nondirect vent capacity then the adequate flow of combustion and ventilating air must not be obstructed from reaching the furnace. Air openings provided for combustion air must be kept free of

obstructions which restrict the flow of air. Airflow restric- tions affect the efficiency and safe operation of the furnace.

Keep this in mind should you choose to remodel or change the area which contains your furnace. Furnaces must have a free flow of air for proper performance.

Provisions for combustion and ventilation air shall be made in accordance with latest edition of Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code,

ANSI Z223.1 -- CAN/CGA B 149.1 or applicable provisions of

the local building codes. Special conditions created by mechanical exhausting of air and fireplaces must be con- sidered to avoid unsatisfactory furnace operation.

OUTSIDE AIR IS RECOMMENDED

The use of indoor air for most applications is acceptable, unless there is the presence of corrosive chemicals or contamination. Certain types of installation will require

the use of outside air for combustion. The following types of installations will require use of

OUTDOOR AIR for combustion, due to chemical exposures:

* Commercial buildings * Buildings with indoor pools * Furnaces installed in "confined" laundry rooms * Furnaces installed in "confined" hobby or craft rooms * Furnaces installed near chemical storage areas.

Exposure to the following substances in the combustion air supply will also require OUTDOOR AIR for combustion:

* Permanent wave solutions * Chlorinated waxes and cleaners

* Chlorine based swimming pool chemicals * Water softening chemicals * Deicing salts or chemicals

* Carbon Tetrachloride * Halogen type refrigerants

* Cleaning solvents (such as perchloroethylene) * Printing inks, paint removers, varnish, etc. * Hydrochloric acid * Cements and glues * Antistatic fabric softeners for clothes dryers * Masonry acid washing materials

18-CD19D8-15 7

.....\ /

Furnace locations may be in a "confined space" or an "unconfined space".

Unconfined space is defined in Figure 6. These spaces may have adequate air by infiltration to provide air for combustion and ventilation. Buildings with tight construction (for example, weather stripping, heavily insulated, caulked, vapor

barrier, etc.), may need additional air to be provided as

described for confined space. Confined spaces are installations with less than 50 cu. ft. of

space per 1000 BTU/hr input from all equipment installed.

Air for combustion and ventilation requirements can be

supplied from inside the building as in Figure 9 or from the outdoors, as in Figure 10.

Q MINIMUM AREA IN SQUARE FEET

FOR UNCONFINED SPACE INSTALLATIONS

FURNACE WITH 8 FT. CEILING

MAXIMUM BTUH MINIMUM AREA IN SQUARE FEET

INPUT RATING OF UNCONFINED SPACE

60,000 375

80,000 500 100,000 625 120,000 875

® -I

m FURNAOF

CONFINED

SPACE

All air from inside the building as in Figure 9: The

confined space shall be provided with two permanent openings communicating directly with an additional

room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space.

The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Refer to Table 2 for minimum open areas requirements.

All air from outdoors as in Figure 10: The confined space

shall be provided with two permanent openings, one commencing within 12 inches of the top and one com- mencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. Refer to Table 2, for minimum open areas requirements.

MINIMUM FREE AREA IN SQUARE INCHES

EACH OPENING FURNACE ONLY)

Furnace

Maximum

BTUH/INPUT

Rating

60,000 80,000

100,000 120,000

From

Inside

LESS THAN 50 CU. FT. PER 1000 BTU/HR. INPUT

ALL EQUIP. INSTALLED

TABLE 2

Air

lOO lOO

lOO 12o

Air From Outside

Vertical

Duct

15 20

25 30

Horizontal

Duct

30 40

50 60

Page 8

iiiiiiiiiiii

Installer's Guide

CONFINED SPACE AIR FROM INSIDE BUILDING

CONFINED SPACE

CONFINED SPACE AIR FROM OUTDOORS

CONFINED- SPACE

CONFINED SPACE k AIR FROM VENTILATED ATTIC/CRAWL SPACE

_ ATTIC LOUVERS

CONFINED - AIR SPACE

ALTERNATE INLET

INLET A_R _ AIR DUCT

PERMANENT OPENINGS

,UTLET

DOORS

DUCT CONNECTIONS

Air duct systems should be installed in accordance with standards for air conditioning systems, National Fire Protec- tion Association Pamphlet No. 90. They should be sized in accordance with ACCA Manual D or whichever is applicable.

Central furnaces, when used in connection with cooling units, shall be installed in parallel or on the upstream side of the cooling coil to avoid condensation in the heat exchanger. With a parallel flow arrangement, the dampers or other means used to control flow of air shall be adequate to prevent chilled air from entering the furnace, and if manually operated, must be equipped with means to prevent operation of either unit unless the damper is in full heat or cool position.

On any job, flexible connections of nonflammable material may be used for return air and discharge connections to prevent transmission of vibration. Though these units have been specifically designed for quiet, vibration free operation, air ducts can act as sounding boards and could, if poorly instMled, amplify the slightest vibration to the annoyance level.

When the furnace is located in a utility room adjacent to the living area, the system should be carefully designed with returns to minimize noise transmission through the return air grille. Although these furnaces are designed with large blowers operating at moderate speeds, any blower moving a high volume of air will produce audible noise which could be objectionable when the unit is located very close to a living

area. It is often advisable to route the return air ducts under the floor or through the attic. Such design permits the

installation of air return remote from the living area (i.e. central hall).

When the furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace and terminating outside the space containing the furnace.

RETURN AIR DUCT SYSTEMS

Where there is no complete return duct system, the return connection must be run full size from the

furnace to a location outside the utility room, base- ment, attic, or crawl space.

Do Not install return air through the back of the furnace

cabinet. Do Not install return air through the side of the furnace

cabinet on horizontal applications.

NOTE: Minimum return air temperature is 55 ° F.

CONFINED SPACE AIR FROM VENTILATED ATTIC

CONFINED- SPACE

INLET AIR DUCT

8 18-CD19D8-15

:LOUVERS

TO OUTDOORS

All return air duct systems should provide for installation of return air filters.

1. Set the furnace in place.

2. For upflow side return installations, remove the insula- tion around the opening in the blower compartment.

3. The side panels of the upflow furnace include locating notches that are used as guides for cutting an opening for return air, refer to Figure 11 and the outline drawing on page 4 for duct connection dimensions for

various furnaces.

NOTE: On upflow 5 ton airflow models, if the airflow requirement

exceeds 1800 CFM, these models will require return air openings and filters on both sides; OR 1side and the bottom; OR just the bottom.

Page 9

Installer's Guide

4. Ifa 3/4" flange is to be used for attaching the air inlet duct, add to cut where indicated by dotted lines in Figure 11.

Cut corners diagonally and bend outward to form flange.

5. If flanges are not required, and a filter frame is installed, cut between locating notches (Figure 11).

6. The bottom panel of the upflow furnace must be re- moved for bottom return air. Remove the filter and lay

the furnace on its back. Remove the two 1/4" hex screws securing the bottom front channel to the cabinet. Lower

the front edge of the bottom front channel and pull forward to remove the channel. The bottom return air

panel will now easily slide out of the cabinet. Reinstall the bottom front channel and filter for upflow bottom

return installations.

7. The filter retainer is factory supplied for upflow bottom return. Use the filter retainer on side or bottom if filter

is to be used within the furnace cabinet on upflow only installations.

8. The horizontal installation of the upflow furnace

requires an external filter section. Do NOT use the bottom return filter within the furnace. Filter kits are available for horizontal applications.

9. Connect duct work to furnace. See Outline Drawing for supply and return duct size and location. Flexible duct connectors are recommended to connect both supply and return air ducts to the furnace. If only the front of the furnace is accessible, it is recommended that both supply and return air plenums are removable.

NOTE: On upflow 5 ton airflow models, if the airflow requirement

exceeds 1800 CFM, these models will require return air openings and filters on both sides; OR 1 side and the bottom; OR just the bottom.

The upflow furnace blower door has a hinge at the bottom which allows the door to tilt forward for filter replacement without the door being removed (See Figure 12). The furnace filter in the bottom or side configuration can be removed by simply turning the two latches on the blower door and tilting

the door forward.

The filter rails are spring loaded for automatic adjustment to allow standard size, locally obtainable replacement filters.

The filter rack itself slides to adjust to the required width needed for bottom or side return (See Figure 13).

BOTTOM FILTER RACK INSTALLATION

With the filter removed, the filter rack is compressed and

then inserted into the bottom of the furnace. The retaining screw/pin on each side inserts into engagement holes at the

bottom of the furnace cabinet side.

RETURN AIR FILTERS (NOT SUPPLIED)

TYPICAL UPFLOW RETURN AIR FILTER INSTALLATIONS

Filters are not factory supplied for these furnaces. These furnaces require high velocity type air filters. The filters may

be located within the furnace blower compartment for UPFLOW furnaces in either a BOTTOM or SIDE (left side or

right side) return air inlet. Some filters may need to be trimmed for side or bottom filter use.

TABLE 3

MODELS CABINET FILTER

NUMBERS WIDTH QTY & SIZE

*UX2B060A9362A *UX2B080A9422A

*UX2C100A9482A 21" 1 - 20" X 25" X 1" *UX2D120A9602A 24-1/2" 1 - 24" X 25" X 1"

* Firstletter may be "A" or "T"

** NOTE - On 5 ton airflow models, if the airflow requirementexceeds

1800CFM, these models will require return air openings andfilters

on bothsides; OR 1sideand the bottom;OR just the bottom.

LOCATING *_ VIDED FOR SIDE

NOTCHES PRO-

RETURN CUTOUT

UPFLOW FURNACE ONLY

17-1/2" 1- 17"X25"X 1"

-,. I/-

4..

j CUT OUT FOR

SIDE FILTER

*- I

Blower Door Hinge and Bottom Filter Rack Installation

FILTER

RACK RAILS

'_ SPRINGS

AUTOMATIC

ADJUSTMENT

RETAINING

(Both Sides)

*SEE OUTLINE DRAWING _ of Furnace

"_ ,_ RONT

18-CD19D8-15 9

Optional Filter Rack Accessory Kit - BAYRACK960A

Page 10

Installer's Guide

",.: ..... ..

_ _ BOTTOM ENGAGEMENT

BlowerDeck _ II Furnace "

Engagement II • " II Cabinet

Filter Rack

Retaining

Screw/Pin Filter

Rack

iiiiiiiiiiii

iiii II _ II Side

ENGAGEMENT

HOLE DETAIL

(Typical both sides

and blower deck) BLOWER EngagementHole

OPTIONAL FILTER RACK INSTALLATION FOR SIDE RE- TURN AIR ON UPFLOW FURNACES (Left or Right)

If side air return is desired, it is necessary to move the filter rack from the bottom of the furnace and reinstall it on the

side. The following instructions should be used:

a. Open or remove the blower door.

b. Remove the filter.

c. Compress the filter rack to disengage the retaining

d. Leave the bottom panel in place. e. After the side cutout is made following the directions

f. Reinstall the furnace filter on the side inserting the

!'" '_" I1..... 11 _lnstallation With_)_Bottom Return

pins/screws from the furnace sides and slide the filter rack out.

in the "Return Air Duct Connections" section on pages 8 and 9, compress the filter rack and reinstall

in the side of the furnace. Confirm that the upper retaining pin/screw locks into the engagement hole in the blower deck and the lower pin/screw rests against the side of the bottom panel. See Figures 15-19.

chamfer end first.

Engagement Hole

For Filter Rack

Installation With

Side Return

Furnace

Cabi net .,.,,)_

Side

Retaining Rack

Screw/Pin Assembly

SIDE

CUTOUT

Furnace

Cabinet

Side

Filter

Rack

RETAINING

PIN -_

Bottom Panel

Furnace Blower Deck

EngagementHole ForFilter Rack

InstallationWith BottomReturn

10 18-CD19D8-15

Filter Rack Retaining

Screw/Pin

(Bo_[__,

III J/ FILTER BOTTOM I I.] JJ RACK PANEL

[[I // RAILS INSTALLED I[ V/zJ Typical Upflow Left Side Return Filter

L_z/Rack Installation

Optional Filter Rack Accessory Kit - BAYRACK960A

Page 11

Typical Upflow Right Side Return Filter Rack Installation

Installer's Guide

BLOWER DOOR/HINGE REMOVAL

If clearance or other problems create a problem in using the tilting door, the blower door hinge may be removed without creating any problems with the seal of the furnace. To remove the blower door, tilt the door forward 2 to 3 inches and pull up. To remove the tilt feature, simply remove the lower hinge as shown in Figure 22. The bottom of the blower door will catch in the bottom of the furnace front channel for door replacement.

CHAMFER

END OF

FILTER GOES

INTO FILTER RACK FIRST

RETURN AIR FILTERS FOR UPFLOW FURNACE IN HORIZONTAL CONFIGURATION

When the Upflow Furnace is installed in the horizontal

configuration, the return air filters must be installed exterior to the cabinet. Remote filter grilles may be used for home- owner convenience or the filters may be installed in the duct work upstream of the furnace. See Figure 21.

Door Hinge Removed

ALTERNATE UPFLOW FILTER CLIP / BRACKET INSTALLATION (KIT09224)

1. Determine the location to be used. The furnace cabinet has dimples for location of the alternate furnace clips

(Side return only). Pre-drill clearance holes with a 3/16" drill. Bottom return holes are pre-drilled.

2. Install the clips in front and rear of the desired location using the screws provided. The filter clip with the leaf spring mounts in the rear of the cabinet.

ALTERNATE FILTER CLIPS LOCATION

TYPICAL RETURN AIR FILTER INSTALLATION IN

UPFLOW MODEL IN HORIZONTAL POSITION

18-CD19D8-15 11

FILTER CLIP - KIT09224

Page 12

Installer's Guide

iiiiiiiiiiii

INSTALLING THE FILTER

The filter may need to be cut to fit the unit depending on the location of the return air filter.

A score line and the words "CUT HERE" are located on the end of the filter. If your application requires cutting the

filter, do so as indicted by the score mark.

UNIT

SIZE

17-1/2"

21"

24-1/2"

TYPICAL DOWNFLOW FURNACE RETURN AIR FILTER INSTALLATIONS

Two filters are factory supplied for each downflow furnace. These furnaces require high velocity type air filters. Down-

flow furnace filters must be located outside the furnace cabinet. Typical installations are shown in Figure 24.

Tables 5 and 6 provide information for installation of the filter retaining brackets shipped with downflow furnaces.

Optional

BAYFLTR206

Door Kit

BOTTOM

DO NOT CUT DO NOT CUT

DO NOT CUT

RETURN AIR

SIDE

DO NOT CUT

CUT ON LINE CUT ON LINE

TABLE 4

MODELS CABINET FILTER

NUMBERS WIDTH QTY & SIZE

*DX060R936

*DX080R942

*DX100R948 21" 2 - 16" X 20" X 1" *DX120R960 24-1/2" 2 - 16" X 20" X 1"

*First letter may be "A" or "T"

LOCATING FILTER RETAINER BRACKETS IN

CABINET RETURNDUCT DIMENSION DIMENSION BRACKET

WIDTH WIDTH "A .... B" LOCATION*

17-1/2" 16-1/4" 15" 14" 14-3/8"

21" 19-3/4" 19-1/2" 14" 13-1/8"

24-1/2" 23-1/4" 22" 14" 13-5/8"

* LOCATION DIMENSION IS FROM END OF DUCT AGAINST THE FURNACE TO THE

SCREW HOLES FOR THE BRACKET.

BOptiyFLnTRI06

17-1/2" 2 - 14" X 20" X 1"

TABLE 5

DUCTWORK

FILTER

Airflow

DOWNFLOW

/ ow% ow;

TABLE 6

MINIMUM CLEARANCE FROM COMBUSTIBLE MATERIALS FOR

UPFLOW/HORIZONTAL AND DOWNFLOW/HORIZONTAL FURNACES

UNIT LOCATION

FURNACE SURFACE

SIDES 0" 1" 0"

BACK 0" 3" 6"

TOP 1" 1" 1"

FRONT 3" 3" 18"

VENT 0" 0" 0"

NOTE: CLEARANCE REQUIRED AT TOP OF PLENUM IS 1"

12 18-CD19D8-15

VERTICAL HORIZONTAL HORIZONTAL

CLOSET CLOSET ALCOVE / ATTIC

Page 13

Installer's Guide

I The following warning complies with State of California law, Proposition 65.

Hazardous Gases! Exposure to fuel substances or by-products of incomplete

fuel combustion is believed by the state of California to cause cancer, birth defects, or other reproductive harm.

Carbon monoxide, fire or smoke can cause serious bodily injury, death, and!or property damage.

A variety of potential sources of carbon monoxide can be

found in a building or dwelling such as gas-fired clothes dryers, gas cooking stoves, water heaters, furnaces and fireplaces. The U.S. Consumer Product Safety Commission recommends that users of gas-burning appliances install

carbon monoxide detectors as well as fire and smoke detec- tors per the manufacturer's installation instructions to help

alert dwelling occupants of the presence of fire, smoke or unsafe levels of carbon monoxide. These devices should be

listed by Underwriters Laboratories, Inc. Standards fbr

Single and Multiple Station Carbon Monoxide Alarms,

UL 2034 or CSA International Standard, Residential Carbon Monoxide Alarming Devices, CSA 6.19

NOTE:

The manufacturer of your furnace does not test any detec-

tors and makes no representations regarding any brand or type of detector.

GENERAL VENTING

THIS FURNACE MUST BE VENTED TO THE OUTDOORS. THESE FURNACES ARE INDUCED DRAFT VENTED

AND MUST NOT BE CONNECTED TO ANY VENT SERV-

ING ANOTHER APPLIANCE. PLEASE NOTE THAT THESE FURNACES USE POSITIVE-PRESSURE VENT SYSTEMS.

Proper venting is essential to obtain maximum efficiency from a condensing furnace. Proper installation of the vent system is necessary to assure drainage of the condensate and prevent deterioration of the vent system.

American Gas Association has certified the design of con-

densing furnaces for a minimum of 0" clearance from com-

bustible materials with a single wall plastic vent pipe.

The recommended system is assembled from 2", 2-1/2", or 3" plastic pipe and fittings (See Table 7, page 15). Where the system is routed to the outdoors through an existing masonry chimney containing flue products from another gas appliance, or where required by local codes, then 3" venting of Type 29-4C stainless steel must be used in place of PVC material.

These furnaces have been classified as CATEGORY IV furnaces in accordance with ANSI Z21.47 "latest edition"

standards. Category IV furnaces operate with positive vent pressure and with a vent gas temperature less than 140 ° F. above the dewpoint. These conditions require special venting systems, which must be gas tight and water tight.

NOTE:

When an existing furnace is removed from a venting

system serving other gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances.

The following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which

could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan, close fireplace dampers.

4. Follow the lighting instructions. Place the appliance

being inspected in operation. Adjust thermostat so

appliance will operate continuously.

5. After it has been determined that each appliance remain- ing connected to the common venting system properly vents when tested as outlined above, return door, win- dows, exhaust fans, fireplace dampers and any other gas-

burning appliance to their previous conditions of use.

If improper venting is observed during any of the above tests, the remaining common venting system must be corrected. Correction could require rerouting or resizing the remaining vent system.

IMPORTANT:

These furnaces may be installed as Direct Vent (sealed com- bustion) or as Nondirect vent (single pipe). The furnaces are shipped DIRECT VENT with sealed combustion.

For DIRECT VENT APPLICATION: The furnaces must be

vented to the exterior of the house and combustion air MUST come through the inlet air pipe FROM OUTSIDE AIR. The pipes

DO NOT have to exit the exterior of the house together or on the same side of the house.

For NONDIRECT VENT APPLICATION: The furnace shall be

vented to the exterior of the house, but combustion air may enter from the surrounding area as long as combustion air requirements are met. (See AIR FOR COMBUSTION AND

VENTILATION)

FURNACE VENT/INLET PIPE INSTALLATION

There are many different variations of the vent/inlet air pipe combination. The vent/inlet air combination used for instal-

lation of these furnaces depends on the needs of the location. However, these guidelines must be followed:

1. The furnace must vent outside the structure.

2. Furnace combustion air requirements must be met for nondirect, single pipe applications (See example on next page).

3. For direct vent application of these furnaces, the vent pipe and air inlet pipe do not have to exit in the same air

space or even on the same surface of the structure.

However, the longest individual pipe will decide the value fbr the longest allowable equivalent vent/inlet air length

as shown in the vent length table.

18-CD19D8-15 13

Page 14

Installer's Guide

NOTE: BAYVENT200* accessories can be used for inlet and outlet

terminals when the pipes do not exit the structure together.

The following are EXAMPLES ONLY:

EX. 1 --

Example 1 shows that the vent may go vertical while the inlet air may be on any side of the structure. The vent pipe would decide the maximum equivalent length for the pipe depending on the furnace and pipe size.

Vent

Air

Inlet =_ Furnace

EX. 2 --

Example 2 shows the vent pipe exhausting through the roof and the inlet air coming from the interior of the house (See Note). The inlet air coming from the interior of the house must meet combustion requirements for area, etc., as shown

in the section AIR FOR COMBUSTION AND VENTILA- TION in this Installer's Guide.

Air_ _ Vent

Inlet_

(See Note)

EX. 4--

The inlet air does not have to come from outside the structure. Example 4 shows the inlet air (See Note), may come from the

attic if the requirements for combustion air are met as shown in the section AIR FOR COMBUSTION AND VENTILATION.

Attic

Vent

_(Soe Note)

FurnaceL

NOTE: ff only the flue gas pipe is to the outside of the structure, a

straight section of pipe (long enough to exit the furnace cabinet) must be attached to the inlet air side with an elbow (which is 5 to 10 equiv, ft.) installed on the end to prevent dust and debris from falling directly into the furnace.

VENT FITTING MATERIAL - PLASTIC

Gas and liquid tight single wall vent fittings, designed for resistance to corrosive flue condensate, MUST be used throughout.

Listed in Table 7 are 2", 2-1/2", and 3" size fittings that meet these requirements. The materials listed are various grades of PVC and ABS plastic.

PIPE JOINTS: All joints must be fastened and sealed to prevent escape of combustion products into the building.

NOTE: It is recommended that the first joints from the furnace be

connected and sealed with high temperature RTV. This will enable the pipes to be removed later without cutting.

EX. 3 --

Example 3 shows the vent exiting one side of the house while the inlet air is on the opposite side of the structure. Here the vent pipe length must be within the allowable length for the size of furnace and size of the vent pipe. This example demonstrates that the pipes do not have to exit on the same

side of the structure.

Air

Inlet

=_ Furnace

14 18-CD19D8-15

Vent

Be sure to properly support these joints.

BONDING OF PVC

Commercially available solvent cement for PVC must be used to join PVC pipe fittings. Follow instructions on con- tainer carefully.

Pipe and Fitting -ASTM D1785, D2466, D2661, & D2665 PVC Primer and Solvent Cement - ASTM D2564

Procedure for Cementing Joints - RefASTM D2855

1. Cut pipe square, remove ragged edges and burrs. Chamfer end of pipe, then clean fitting socket and pipe

joint area of all dirt, grease, moisture or chips.

2. After checking pipe and socket for proper fit, wipe socket and pipe with cleaner-primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe.

DO NOT ALLOW PRIMER TO DRY BEFORE APPLY- ING CEMENT.

3. Apply a thin coat of cement evenly in the socket. Quickly apply a heavy coat of cement to the pipe end and insert pipe into fitting with a slight twisting movement until it

bottoms out.

Page 15

Installer's Guide

4. Hold the pipe in the fitting for 30 seconds to prevent tapered socket from pushing the pipe out of the fitting.

5. Wipe all excess cement from the joint with a rag. Allow

NOTE: Follow venting instructions carefully when using PVC

cemenL

15 minutes before handling. Cure time varies according

to fit, temperature and humidity.

IMPORTANT:

All joints must be water tight. Flue condensate is somewhat acidic, and leaks can cause equipment damage.

TABLE 7

PVC VENT FITTING MATERIAL These fittings are available from your Gas Furnace Distributors.

1-518"

[

i_ 4-1/2"

WALL MOUNT FLANGE

BAY69X 148

PLASTIC PIPE DESIGNATIONS

PVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

F891 CELLULAR CORE "158 ASTM F891

D2665 DWV PIPE *'158 ASTM D2665

D1785 SCH 40, 80, 120 *'158 ASTM D1785

D2241 SDR SERIES *'158 ASTM D2241

CPVC

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2846 CPVC 41 *'212 ASTM D2846

F441 SCH 40, 80 *'212 ASTM F441 F442 SDR SERIES *'212 ASTM F442

ABS

ASTM STANDARD PIPE TYPE ALLOWABLE TEMPERATURE MARKING

D2661 SCH 40 DWV **'180 ASTM D2661

F628 SCH 40 DWV CELLULAR CORE **'180 ASTM F628

* - Allowable temperatures based on classifications covered in ASTM D4396 [Deflection Temps Under Load (264 PSI)] ** - Allowable temperatures based on classifications covered in ASTM D1784 [Deflection Temps Under Load (264 PSI)]

*** - Allowable temperatures based on classifications covered in ASTM D3965 [Deflection Temps Under Load (264 PSI)]

2-3/16"

_----- 5-5/8"

WALL MOUNT FLANGE

BAY69X 147

Connection of the pipe and collar of the combustion air inlet should just be a friction fit. It is recommended that the inlet air joint be sealed with RTV type sealant to allow the joint to

be separated for possible future service. The inlet and vent

pipes must be properly supported throughout the entire length.

Connection of the vent pipe to the vent collar should also be accomplished using RTV type sealant. This type sealant provides a connection which remains flexible and can be separated in the future if service needs require the removal of the vent pipe for service or clearance.

NOTE:

Vent termination kit BAYAIR3OAVENTA or BAYVENT2OOB

may be used in addition to the horizontal and vertical termination options shown in the following figures.

18-CD19D8-15 15

(_ VENT AND INLET AIR CONNECTIONS

Seal VENT PIPE

withRTV sealant

Front of Furnace

Seal INLET AIR PIPE

with RTV sealant

Page 16

Installer's Guide

VENT LENGTH TABLE

iiiiiiiiiiii

ALTITUDE MAXIMUM TOTAL EQUIVALENT LENGTH IN FEET

0-7,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

UX2/DX2B060A9362A 200 200 200 UX2/DX2B080A9422A 50 120 200 UX2/DX2C100A9482A Not Allowed 60 200 UX2/DX2D120A9602A Not Allowed Not Allowed 200

7,000-9,500 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

UX2/DX2B060A9362A 100 100 100 UX2/DX2B080A9422A 25 60 100 UX2/DX2C100A9482A Not Allowed 30 100 UX2/DX2D120A9602A Not Allowed Not Allowed 100

9,500-12,000 Feet 2 INCH PIPE 2.5 INCH PIPE 3 or 4 INCH PIPE

UX2/DX2B060A9362A 50 50 50 UX2/DX2B080A9422A Not Allowed 30 50 UX2/DX2C100A9482A Not Allowed Not Allowed 50

UX2/DX2D120A9602A Not Allowed Not Allowed 50

NOTES: * - First letter may be "A" or "T"

1. Minimum vent length for all models: 3' horizontal or 3' vertical.

2. DO NOT MIX PIPE DIAMETERS IN THE SAME LENGTH OF PIPE OUTSIDE THE FURNACE CABINET (Except adapters at the top of the furnace). If different inlet and vent pipe sizes are used, the vent pipe must adhere to the

maximum length limit shown in the table above (See note 6 below for exception). The inlet pipe can be of a larger diameter, but never smaller than the vent pipe.

3. MAXIMUM PIPE LENGTHS MUST NOT BE EXCEEDED! THE LENGTH SHOWN IS NOT A COMBINED TOTAL, IT IS THE MAXIMUM LENGTH OF EACH (Vent or Inlet air pipes).

4. One SHORT radius 90° elbow is equivalent to 10' of 3" pipe and one LONG radius elbow is equivalent to 6' of 3" pipe. One 90° elbow is equivalent to 71/2' of 21/2'' pipe or 5' of 2" pipe. Two 45° elbows equal one 90°elbow.

5. The termination tee or bend must be included in the total number of elbows. If the BAYAIR30AVENTA termination kit is used, the equivalent length of pipe is 5 feet. BAYVENT200B equivalent length is 0 feet.

6. Pipe adapters are field supplied (except 120).

FOR VENT AND INLET AIR (SEE NOTES)

HORIZONTAL INSTALLATION (Upflow/Horizontal or Downflow/Horizontal)

NOTE: In horizontal venting when the factory supplied "off-set" (2)(3

reducing coupling) is used for 3" vent pipe installation, make sure the marking "Top" is located on the top side of the pipe.

The straight side must be on bottom for proper condensate

drainage. This coupling is factory supplied only with the

followinomodels: UC120 & DC120. UX120 & UY120

UXIO0 _ UYIO0, UX808C960, and all DX & DY models.

LABEL

SAYS

\\\\\

"TOP"

2" _' COUPLING

FACTORY SUPPLIED ONLY WITH

THE FOLLOWING MODELS:

UC120 & DC120 UX120 & UY120

UX100 & UY100 UX080C960

ALL DX & DY MODLES

16 18-CD19D8-15

VENT OUTLET

Page 17

Installer's Guide

ELBOW AND TEE MUST BE AS CLOSE TOGETHER AS POSSIBLE

iiiiliiiiii;iiiiiiliiliiliiliiliiliiliiliiliiliilli!ii¸

40" UPFLOW OR DOWNFLOW MODELS

COMBUSTION AIR INLET

POSSIBLE CONFIGURATIONS FOR TWO PIPE VENTING SYSTEMS

NOTE: VENT AND INL ET MUS T BE SUPPOR TED

SEE VENTING TABLE

STRAPS OR OTHER SUITABLE SUPPORTS AT MAXIMUM OF 3'-0" INTERVALS

UPWARD PITCH -- 1/4" PER FOOT FIRST SUPPORT SHOULD BE AS

CLOSE TO FURNACE CONNECTION AS POSSIBLE.

NOTE:ANY FITTINGS PASSING

THROUGH AN UNHEATED SPACE

MUST BEINSULATED.

45° ELBOW

USE ONLY

APPROVED STRAP

TERMINATION (FIELDSUPPLIED)

--) / VENT X

OUTSIDE I 1"_+1/2"

WALL

A T A MAXIMUM OF 3' INTER VALS

COMBUSTION AIR

BAYAIR3OAVENTA

ELBOW (FIELD

SUPPLIED)

COMBUSTION AIR

RAIN CAI

OUTSIDE

WALL

STUB CUT AT

45 °ANGLE

18-CD19D8-15 17

Page 18

Installer's Guide

VENT CAP

MAINTAIN 12" (18" FOR CANADA) MINIMUM

CLEARANCE ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE WHICHEVER IS GREATER

BAYVENT200B

12"MINIMUM

TO OVERHANG

COUPLING

( 1" ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE )

( PLASTIC

1" CLEARANCE SNOW ACCUMULATION (AIR SPACE )

VENTINGTHROUGH COMBUSTIBLEWALLS

CLEARANCE (0" ACCEPTABLE FOR PVC VENT PIPE )

COUPLING

( PLASTIC

VENTING ) /

14 61N. MIN. I_--

j lj(TOJOINT)_

_'_ PVC WALL

STU r I MOUNT FLANGE

• II / APPROVED

NORMALLY EXPECTED

Pitch-- 1/4Inch PerFL

PVC WALL

MOUNT FLANGE

IOPTIONAL)

APPROVED

TERMINATION

12" MIN. ABOVE

BAYAIR30AVENTA

NORMALLY EXPECTED SNOW ACCUMULATION

(Sidewall)

When the vent pipe is exposed to temperatures below freezing, i.e., when it passes through unheated spaces, etc., the pipe must be insulated with 112 inch (22.7 mm) thick Armaflex-type insulation or equal.

If the space is heated sufficiently to prevent freezing, then the insulation would not be required. If domestic water pipes are not protected from freezing then it is assumed the space meets the condition of a heated space.

HORIZONTAL VENTING THROUGH WALL

These furnaces may be installed as direct vent (as shipped) or as nondirect vent. Installation must

conform to national, state, and local codes. The vent & inlet terminals must be located at least 12"

minimum above normally expected snow accumulation level. Avoid areas where staining or condensate drippage may be

a problem. Location of the vent/wind terminal should be chosen to meet the requirements of Figure 39 for either direct or nondirect

vent applications. PITCH -- Venting through the wall must maintain 1/4" per

foot pitched upward to insure that condensate drains back to the furnace.

FLUE GAS DEGRADATION -- The moisture content of the flue gas may have a detrimental effect on some building

18 18-CD19D8-15

VENTING THROUGH NON-COMBUSTIBLE WALLS

Pitch- 1/4 Inch PerFt.

materials. This can be avoided by using the roof or chimney venting option. When wall venting is used on any surface that

can be affected by this moisture, it is recommended that a corrosion resistant shield (24 inches square) be used behind

the vent terminal. This shield can be wood, plastic, sheet metal, etc. Also, silicone caulk all cracks, seams and joints

within 3 feet of the vent terminal.

COMBUSTIBLE MATERIAL WALL

A minimum clearance of 1" to combustible materials must be maintained when using single wall stainless steel venting. See Figure 31.

Shield material to be a minimum of 24 gauge stainless or aluminized sheet metal. Minimum dimensions are 12"x12".

Shield must be fastened to both inside and outside of wall. Use screws or anchor type fasteners suited to the outside or

inside wall surfaces.

NONCOMBUSTIBLE MATERIAL WALL

The hole through the wall must be large enough to maintain pitch of vent and properly seal.

Use cement mortar seal on inside and outside of wall. See Figure 32.

Page 19

Installer's Guide

SUPPORT HORIZONTAL PIPE EVERY 3' 0" WITH THE FIRST SUPPORTAS CLOSE TO THE FURNACE AS POSSIBLE. INDUCED

DRAFT BLOWER, HOUSING, AND

WEIGHT OF THE FLUE PIPE.

FURNACE MUST NOT SUPPORT THE {_ {_ I_ I_

__ | _-I PITCH - t $4" PER FOOT

40" UPFLOVV OR.DO".rv_FLOW FURNACE

HORIZONTAL AND VERTICAL

REMOVE RIBS FROM

VERTICAL

VENT

DISTANCE FROM TOP OF VENT TO BO1TOM OF AIR INLET MUST I

REMOVE RIBS ,_ FROM CAP

COMBUSTION

ROOF BOOT

(FIELD SUPPLIED)

AIR

VENT"_

12' :t I"_

9" MIN.

_ 12-INCH CLEAr4ANCE MUST BEMAINTAINED ABOVE HIGHEST / I I _ MAXIMUM NOT TO EXCEED

COMBUSTION AIR INLET

VENT

AN_C!PATED SNOW LEVEL 24 INCHES ABOVE ROOF,

MAINTAIN 12 IN. (18 IN. FOR CANADA)

MINIMUM CLEARANCE

ANTICIPATED SNOW LEVEL. MAXIMUM OF

_ ABOVE HIGHEST

24 IN. ABOVE ROOF

suP

(FIELD SUPPLIED)

MAINTAIN 12 IN. (18 IN. FOR CANADA)

ABOVE HIGHEST ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF.

_ SEAL BETWEEN FLANGE, PIPE,

COUPLING AND METAL PANEL WITH HI TEMP RTV SILICONE SEALANT

SUPPORT

FLANGE

PIPE

COUPLING

BAYAIR30AVENTA (VERTICAL)

18-CD19D8-15 19

ELBOW

(FIELD SUPPLIED)

COMBUSTION

AIR

GALVANIZED FIRESTOP SHOULD BE FABRICATED WITH 3-7/8" DIA.

HOLE FOR SUPPORT FLANGE (12" x 12" PANEL OR 12" DIA MIN.)

CLEARANCE (0" ACCEPTABLE FOR PVC VENT PIPE)

( 1 " ACCEPTABLE FOR TYPE 29-4C STAINLESS STEEL VENT PIPE )

CEILING

VENTING THROUGH CEILING

Page 20

Installer's Guide

VENTING THROUGH THE ROOF When penetrating roof with a 2" PVC vent pipe, a 2" electrical

conduit flashing may be used for a weather tight seal. Lubricate flexible seal on flashing before PVC pipe is pushed through the seal. (Field Supplied)

NOTE: No vent cap as shown in Figure 34 is the preferred method

for vertical vent termination in extremely cold climates.

In extreme climate conditions, insulate the exposed pipe above the roof line with Armaflex type insulation.

VENT FITTING MATERIAL - STAINLESS STEEL

Gas and liquid tight single wall metal vent fitting, designed for resistance to corrosive flue condensate such as Type 29-4C MUST be used throughout.

These fittings and fitting accessories are to be supplied locally.

DIRECTION OF STAINLESS STEEL FITTING

Allstainlesssteelfittingmustbeinstalledwithmaleend

towards the furnace.

................................................................................All horizontal stainless steel sections must be positioned

with the seam on top. All long horizontal sections must be supported to prevent

sagging. All pipe joints must be fastened and sealed to prevent escape

of combustion products into the building.

FLUE PIPE

COUPLING TO SUPPORT PIPE FROM ANGLES OR OTHER SUITABLE SUPPORT METHOD

PVC PLASTIC VENTING - ONLY

THROUGH UNUSED CHIMNEY

STAINLESS STEEL

VENT CAP

6 IN. MIN.

FLUE PIPE

SUPPORT THE SINGLE WALL FLUE PIPE AND CENTER IT IN THE CHIMNEY OPENING WITH ANGLES AS SHOWN OR ANOTHER EQUIVALENT MANNER.

COUPLING

AS REQUIRED

(1"ACCEPTABLE FOR TYPE29-4C STAINLESS STEELVENT PIPE)

SEAL BETWEEN FLANGE, PIPE,

COUPLING AND METAL PANEL

WITH HI TEMP RTV SILICONE SEALANT

SUPPORT _

FLANGE

FLOOR

(0"ACCEPTABLE FOR PVC VENT PIPE)

CLEARANCE

COUPLING

GALVANIZED PANEL (FIRESTOP)

FLUE PIPE

TYPE 29-4C STAINLESS STEEL VENTING -

USED THROUGH CHIMNEY THAT VENTS

ANOTHER GAS APPLIANCE

STAINLESS STEEL

VENT CAP

(OPTIONAL)

SEE CAUTION 6 IN. MIN.

SUPPORT THE SINGLE WALL STAINLESS STEEL GAS

VENTING AND CENTER IT IN

THE CHIMNEY OPENING WITH ANGLES AS SHOWN OR

ANOTHER EQUIVALENT MANNER.

NOTE: HORIZONTALVENTING

TO VERTICAL VENTING

NOTE: HORIZONTALVENTING

TO VERTICALVENTING

Do not run vent through chimney for wood burning or

oil furnaces or incinerators or any other gas appliance.

IMPORTANT-

The single wall flue pipe joints must be sealed. The 90° elbow connection to vertical pipe must be sealed to

prevent condensate leakage to base of masonry chimney.

VENTING ROUTED THROUGH A MASONRY CHIMNEY

20 18-CD19D8-15

Do not run vent through chimney for wood burning or oil

furnaces or incinerators.

If remaining free area between single wall flue pipe and masonry chimney is to be used for another gas appliance

venting area must be sufficient to vent that appliance and that appliance must be connected to chimney with separate entry openings.

IMPORTANT-

The single wall flue pipe joints must be sealed. The 90 ° elbow connection to vertical pipe must be sealed to

prevent condensate leakage to base of masonry chimney.

Page 21

Installer's Guide

HORIZONTAL VENT CLEARANCES

INSIDE

CORNER DETAIL

FV'] VENTTERMINAL (_) AIR SUPPLY INLET [] AREAWHERE TERMINAL IS NOT PERMITTED

Non-Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch, deck, or

A= balcony 12 inches (30 cm) 12 inches (30 cm)

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),

B= Clearance to window or door that may be opened 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 4 feet (1.2m) below or to the side of opening;

C= Clearance to permanently closed window

Vertical clearance to ventilated soffit located above

D= the terminal within a horizontal distance of 2 feet

(61 cm) from the center line of the terminal

E= Clearance to unventilated soffit

F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line extended 3 feet (91 cm) with a height 15 feet (4.5 m) above the

above meter/regulator assembly meter/regulator assembly

I= Clearance to service regulator vent outlet 3 feet (91 cm)

Clearance to nonmechanical air supply inlet to 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),

J= building or the combustion air inlet to any other 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 4 feet (1.2 m) below or to side of opening;

appliance 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within

Clearance above a paved sidewalk or paved 7 feet (2.13 m) 1 7 feet (2.13 m)

L= driveway located on public property

M= Clearance under veranda, porch, deck, or balcony 12 inches (30 cm) Notes:

1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.

1. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. :l:. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

and =/< 100,000 Btuh (30 kw), 1 foot (0.3m) above opening. 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw)

and =/< 100,000 Btuh (30 kw), 1 foot (300 m) above opening

10 feet (3m) horizontally

18-CD19D8-15 21

Page 22

iiiiiiiiiiiii

iiiiiiiiiiii

Installer's Guide

Direct Vent Terminal Clearances

Canadian Installations US Installations

Clearance above grade, veranda, porch,

A= deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

B= Clearance to window or door that may be 12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw)

opened and =/< 100,000 Btuh (30 kw), and =/< 50,000 Btuh (15 kw),

C= Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the terminal within a

horizontal distance of 2 feet (61 cm) from the center line of the terminal

E= Clearance to unventilated soffit

F= Clearance to outside corner

G= Clearance to inside corner

Clearance to each side of center line 3 feet (91 cm) with a height 15 feet (4.5 m) above the

extended above meter/regulator assembly meter/regulator assembly

I= Clearance to service regulator vent outlet 3 feet (91 cm)

Clearance to nonmechanical air supply 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),

J= inlet to building or the combustion air and =/< 100,000 Btuh (30 kw), and =/< 50,000 Btuh (15 kw),

inlet to any other appliance 36 inches (91 cm) for appliances > 100,000 Btuh (30 kw) 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw)

K= Clearance to a mechanical air supply inlet 6 feet (1.83m) 3 feet (91 cm) above if within 10 feet (3m) horizontally

Clearance above a paved sidewalk or

L= paved driveway located on public property 7 feet (2.13 m) l-

M= Clearance under veranda, porch, deck, 12 inches (30 cm) :l:

or balcony

Notes:

1. In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code.

2. In accordance with the current ANSI Z223.1/NFPA 54 National Fuel Gas Code.

1-. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwelling and serves both dwellings. :l:. Pemitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

* Clearance in accordance with local installation codes and the requirements of the gas supplier and the manufacturer's Installation Instructions.

6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw), 6 inches (15 cm) for appliances =/< 10,000 Btuh (3 kw),

36 inches (91 cm) for appliances > 100,000 Btuh (30 kw) 12 inches (30 cm) for appliances > 50,000 Btuh (15 kw)

12 inches (30 cm) for appliances > 10,000 Btuh (3 kw) 9 inches (23 cm) for appliances > 10,000 Btuh (3 kw)

DOWNWARD VENTING

Furnace may be in vertical or horizontal configurat_

All horizontal pipes must be

supported at maximum of 3

foot intervals

Slope 1/4" per ft. \ II

Slope 1/4" per ft.

NOTES:

A) Condensate trap for vent pipe must be a minimum of 6 inches in height.

B) Condensate trap for vent and inlet pipe must be connected into a condensate drain pump; an open or

vented drain; or it can be connected to the outlet hose of the furnace's condensate trap. Outdoor drain- ing of the furnace and coil condensate is permissible if allowed by local codes. Caution should be taken

to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Exces- sive draining of condensate may cause saturated ground conditions that may result in damage to plants.

c) The condensate trap should be primed at initial start up prior to heating season operation.

I I

DOWNWARD VENT LENGTH IS

LIMITED TO A MAXIMUM OF 15

S EQUIVALENT FEET.

SEE __ Upflow or NOTES Downflow

6" Min.

.._!._

40 Inch

Furnace

22 18-CD19D8-15

Page 23

Installer's Guide

IMPORTANT:

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through - the - wall vented gas appliances as follows:

For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall

horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back- up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard

wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or

structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon

monoxide detectors a. In the event that the side wall horizontally vented

gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent

floor level.

b. In the event that the requirements of this

subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be

installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required

in accordance with the above provisions shall comply with NFPA 720 and be ANSI!UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the

building at a minimum height of eight (8) feet above grade

directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. This appliance requires a special venting system. If BAYAIR30AVENTA or BAYVENT200B are used, a copy of

the installation instructions for the kit shall remain with the appliance or equipment at the completion of

installation. The venting system installation instructions can be obtained from the manufacturer by writing to the following address:

American Standard, Inc.

6200 Troup Highway Tyler, TX 75707

Attention: Manager of Field Operations Excellence

IMPORTANT: Products installed in Canada must use vent systems that

are certified to the Standard for Type BH Gas Venting Sys- tems (ULC $636) for Class II-A venting systems (up to

65°C). Components of the vent system must not be inter- changed with other vent systems or unlisted pipe or fittings.

Plastic components, specified primers, and glues must be from a single system manufacturer and not intermixed with other system manufacturer's vent system parts. In addi- tion, the first three feet of the vent pipe must be visible for inspection.

18-CD19D8-15 23

Page 24

Installer's Guide

CONDENSATE DRAIN INSTRUCTIONS

IV!_ [q:la//[e] _I

It is recommended that a drain pan be installed under the furnace to prevent property damage, personal injury or death from leaking condensate.

VERTICAL APPLICATIONS Upflow furnace - The connection tubing for left and right

side drainage is shipped in the blower compartment. Install the connection tubing from the trap to the side of the unit and trim all excess tubing to avoid ldnks.

Downflow furnace - The furnace is shipped with the left side drainage setup. To change the right side drain, remove the drain lines from the trap, rotate the trap 180 ° so it exits to the right, reconnect the lines, and run a 1/2" CPVC pipe from the trap out through the right side knock-out. Use RTV silicone sealant to connect the CPVC pipe to the trap for ease of removing to clean the trap.

UPFLOW (VERTICAL)

Left side

Right side

UPFLOW (VERTICAL)

Use

extension hose here

Use Inducer Drain

hose without

extension

UPFLOW HORIZONTAL 17" UNITS

(Left side only)

24 18-CD19D8-15

UPFLOW HORIZONTAL 21" & 24" UNITS

(Left side only)

Page 25

HORIZONTAL APPLICATIONS

Upflow and Downflow furnaces - All horizontal applica- tions are left side only. It is always recommended that the auxiliary drain pan be installed under a horizontally in- stalled evaporator and/or 90% gas furnace. Connect the auxiliary drain pan to a separate drain line (no trap is needed

in this line).

The trap must be repositioned to the exterior of the cabinet. Remove the trap from its present location and reposition the trap outside of the unit, through the long circular hole, next to the secondary recuperative cell. Remove the larger &'ain line (from the secondary cell) and trim to fit between the second- ary cell and the new trap location. On upflow units, plug the hole in the blower deck where the tube went through.

DOWNFLOW (VERTICAL)

Installer's Guide

Cut off curved end of

Inducer drain hose

DOWNFLOW (HORIZONTAL)

Remove the hose from the induced blower and reposition into the other &'ain tap of the inducer, which is located 90 ° clockwise around the inducer. Move the cap from that &'ain tap to the unused drain tap. On upflow units, plug the hole in the blower deck where the tube went through. This tube on

downflow units will need to be cut to fit between the inducer and the trap. On upflow units, this tube may need to be

extended, using the tubing shipped with the furnace. Connections must be made to an OPEN/VENTED DRAIN. Outdoor draining of the furnace and coil condensate is

permissible if allowed by local codes. Caution should be taken to prevent drains from freezing or causing slippery conditions that could lead to personal injury. Excessive draining of condensate may cause saturated ground conditions that may result in damage to plants.

NOTE:

Use 1/2" or larger PVC or CPVC pipe and fittings as required

for drain connections (fittings, pipe and solvent cement not

provided).

NOTE: A corrosion resistant condensate pump must be used ifa

pump is required for a specific drain system.

Use CPVC tubing from Trap outlet,

over burner box to cabinet exit

DOWNFLOW (VERTICAL)

18-CD19D8-15 25

Right

side

IMPORTANT:

The condensate drain should be installed with provisions to prevent winter freeze-up of the condensate drain line. Frozen condensate will block drains, resulting in furnace shutdown, ff the drain line cannot be installed in a conditioned space, then

UL listed heat tape should be applied as required to prevent freezing (per manufacturer's instructions). The heat tape should be rated at 5 or 6 watts per foot at 120 volts. Self-regulating (preferred) or thermostatically controlled heat tape is required.

Evaporator and furnace condensate drain piping may be manifolded together. A primary drain vent stack must be installed and terminated below the outlet of the secondary heat exchanger drain connection to prevent water from damaging furnace controls if the primary drain outlet plugs up. Where the furnace is installed above a finished ceiling, the primary drain vent stack must be installed such that overflow from the vent stack opening will flow into an axillary drain pan in order to prevent water damage to the finished ceiling below.

Page 26

Installer's Guide

If upflow furnace is installed over a finished ceiling, overflow

from the primary drain vent stack must flow into an auxiliary drain pan to prevent damage to the finished ceiling below,

Primary drain vent stack must terminate below

secondary heat exchanger condensate drain outlet,

To drain opening

",,,

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE

SEE

NOTE 7

2STAGE

FURNACE

[]

T"STAT

[]

SEE

NOTE 8

[] []

[]

1 TER COMPO[ENT ,,MIRI G

24 V. "L FIELD

---- L ]NE v. _* M_'I_ [NG 24 V. _ FA;T{ _Y

-- L ]NE /.#>" 'A,'IR [MG

SEE

NOTE 6

[]

_]-_

[]

USING A 1 STAGE HEATING THERMOSTAT

1 STAGE HEATING

NO COOLING

NOTES:

I BE SURE POWER AGREES WITH EOglPMENT NAMPLATE(S)

2 LOW VOLTAGE (24V AIRING) TO BE NO 18 AW G MIN 3 GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES

SET THERMOSTAT HE_T ¢_TI_IPATOR PER UNIT AIRING DIAGR&M

: THESE LEADS PNOVIDE ,,yS ' ROWER FOR CO_'iMECTION OF ELECTRONIC AIR

CLEANER AND HUMIDIFIER MAX LOAD I0 AMPS EACH

6 THIS CONNECTION IS ONLY USED FOR THERMOSTATS REOUIRIMG

CONNECTION TO THE 24 V POWER SUPPLY (COMMAN)

7 SEE TWINNING CONNEDTION DIAGRAMS FOR PROPER CONNECTIONS

WHEX USING THIS FEATURE

8 WHEN A HEATING THERMOSTAT (WITHOUT FAN SWITCH) IS USED,

NO WIRING ON "G" TERMINAL OF IFD IS USED

9 AI _NI} A2 MilST BE JUM_ERED TOGETHER FOR _ROPER OPERATION

SECOND STAGE HEATING AILL BEGIN I0 MINUTES AFTER FIRST STAGE

_FIELD ADDED JUMPER • GROU N D

WlTOW2. \SCREW

{

T'STAT

SEE

NOTE 7

2 STAGE

FURNACE

-D

D D

SEE

NOTE 6

INTER CII,!f:C ENT ',A"IF_]N("

24 V'. -L_ FIELD

----LINE ,/.j,/WIRI[ G

2 'M'. _, FACT Ow, Y

-- LINE ',,'. _,

Fq @

'_'11_I O

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE

2 STAGE HEATING

USING A 2 STAGE HEATING THERMOSTAT

NO COOLING

NOTES'

BE SURE POWER AGREES WITH EQUIPMENT NAMPLATE(S).

LOW VOLTAGE (24V, WIRING) TO BE NO, 18 A.W,G. MIN.,

GROUNDING OF EQUIPMENT MUST COMPLY WITH LOCAL CODES.

SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.

THESE LEADS PROVIDE 115 V. POWER FOR CONNECTION OF ELECTRONIC AIR CLEANER AND HUMIDIFIER MAX, LOAD 1.0 AMPS EACH.

THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING CONNECTION TO THE 24 V. POWER SUPPLY (COMMON) SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS WHEN USING THIS FEATURE,

From Dwg. 21B342024 Rev. 0

26 18-CD19D8-15

Page 27

OUTDOOR UNIT

(NO TRANSFORMER)

Installer's Guide

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE

2 STAGE HEATING, 1 STAGE COOLING

USING A 2 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

T'STAT

NOTE 7

D Fq

2 STAGE

FURNACE

SEE

NOTE 8 D

t-q

t--q

NOTES:

I. BE SURE POWERAGREES WITH EQUIPMENT NAMPLATE(S)

2. LOWVOLTAGE (24V. WIRING) TO BE NO. 18 A.W.G. MIN..

3. GRO DIG OF EQ IPMENT MUST COMPLYWITH LOCAL CODES

4. SET THERMOSTATHEAT ANTICIPATOR PER U IT WIRING DIAGRAM

5. THESE LEADS PROVIDE 115 V. POWERFOR CON ECTION OF ELECTRONIC AIR CLEA ER AND HUMIDIFIER MAX. LOAD 1.0 AMPS EACH.

6. THIS CONNECTION IS ONLY USED FOR THENMOSTATSREQUIRING CONNECTION TO THE 24 V. POWERSUPPLY. (COMMO)

7. SEE TWINNING CO NECTION DIAGRAMS FOR PROPERCONNECTIONS WHE USING THIS FEATURE

8. THE "Y" TERMINI AL FROM THE THERMOSTATM ST BE WIRED TO THE "Y" TERMINAL OF THE FURNACECO TROL FOR PROPERBLOWER

OPERATION DUAl G COOLING.

OUTDOOR UNIT

(NO TRANSFORMER)

SEE

NOTE 6 @

INTE:_ COM:_ONENT WIRING

24 V. \ FIELD

----LINE Y._ WIR ING 24 V. _ FACTORY

--LINE Y._ WIRIN(

FIELD WIRING DIAGRAM FOR 2 STAGE FURNACE

2 STAGE HEATING, 1 STAGE COOLING

USING A 1 STAGE HEATING, 1 STAGE COOLING THERMOSTAT

(OUTDOOR SECTION WITHOUT TRANSFORMER)

T'STAT

NOTE 7

.N_O_T_E_S_

......

E_---

INTER COMPONENT WIRING

...... 24 V. \ FIELD

----LINE V.TW]RING 24 V. "'_ FACTORY

--LINE V._y WIRING

SEE

2 STAGE

FURNACE

-B

---D

--D

--[_.

- - [_1

TO 115Vl PH.,

i i

60 HZ.,POWER SUPPLY PER LOCALCODES

HUM SEE NOTE5

EAC SEE

NOTE5

NOTES:

I. BE SURE POWERAGREES WITH EQUIPMENT NAMPLATE(S).

2. LOW VOLTAGE (24V. WIRING) TO BE NO. 18 A.W.G. MIN..

3. GROUNDINGOF EQUIPMENT MUST COMPLY WITH LOCAL CODES.

4. SET THERMOSTAT HEAT ANTICIPATOR PER UNIT WIRING DIAGRAM.

5. THESE LEADS PROVIDE 115 V. POWERFOR CONNECTION OF ELECTRONIC AIR CLEANER AND HUMIDIFIER MAX. LOAD I.O AMPS EACH.

6. THIS CONNECTION IS ONLY USED FOR THERMOSTATS REQUIRING CONNECTION TO THE 24 V. POWERSUPPLY. (COMMON)

7. SEE TWINNING CONNECTION DIAGRAMS FOR PROPER CONNECTIONS WHEN USING THIS FEATURE,

8. THE "Y" TERMININAL FROM THE THERMOSTAT MUST BE WIRED TO THE "Y" TERMINAL OF THE FURNACE CONTROL FOR PROPER BLOWER

OPERATION DURING COOLING.

9. Wl AND W2 MUST BE JUMPERED TOGETHER FOR PROPER OPERATION. SECOND STAGE HEATING WILL BEGIN I0 MINUTES AFTER FIRST STAGE.

FIELD ADDED _--_f,- ..................F U R N A C E

JUMPER (NOTE 9) ,I I ! _b iK! JUNCTION

['-LH B,<L_]_]_ I BOX

TO115V1 PH,, I .... "_'_' WH/II

60 HZ., POWER J I _ 11

SUPPLYPER 1 I I'm I

'T GROUND

\ SCREW

LOCALCOOES| ,N ._______£_

rwH/I -- ,

HUM SEE J -- ,,_11 I

NOTE__ I

EAC SEE NOTE 5 , B_< From Dwg. B342019 Rev. 0

I ,,

From Dwg. B342021 Rev. 0

18-CD19D8-15 27

Page 28

Installer's Guide

TWINNING CONNECTION DIAGRAM

FOR TWINNING UX/DX-R FURNACES

1 STAGE HEAT / 1 STAGE COOLING THERMOSTAT

OUTDOOR UNIT NO. 1 1 STAGE

(WITH TRANSFORMER) HEATING / COOLING

SEE NOTE 3 THERMOSTAT FURNACE NO. 1

I :Ul

[ @@-(_ OI

(F_ELO SUPPUEO>

A_ERNaTE CONNECTION

OUTDOOR UNIT NO. 1

(NO TRANSFORMER)

ON BOTH UNITS.

2ND STAGE WILL FIRE

10 MINUTES AFTER 1ST i

SEE NOTE 5

• i

NOTES

FURNACE NO. 2

SLOWEn OPERATION OF

UNIT NO 2 IS SYNCRONIZED

WITH UNIT NO I VIA SIGNALS

FROM TWIN CONNECTION

SEE NOTE 4

..... i

l l

,.J

I _OTN FURNACESMUST3_ ROWERE_FRON

THE SANE _lGV LEGOF D_RCNIT PANEL¸

2 _NSURE 24V FURNACE TRANSFORMERS ARE

IN PHASE PRIOR TO COMPLETING CONNECTIONS,

CHECK VOITAGE BET_EN "R" TERMINAIS OF EACH FURNACE 1{ VOLTAGE fS GREATER THAN

/OV, REVERSE THE BL AN RD SECONDARY LEADS

ON ONE OF THE FURNACE TRANSFORNERS

IF OUTDOOR UNIT HAS A RAY TRANSFORNER,

AN iSOIATION R{!AY MUST B_ /NSTA!L[D

(FIELD SUPPLIED USE PILOT DUT_ RELAY {'NC'), SUCH AS RLFORZ5) SEE ALT CONNECTION

IF CURRENT EXCEEDS THERMOSTAT CURRENT RATING, US_ ISOLATION RELAYS _'Ri') AS SRO_N _DO NOT CONNECT _ TO #)

_SOLATION RELAY NOT NEEDED IF THE THERNOSTAT CONTACTS AR_ RATED AT I OA OR A_OV_

CONNECTION MAY _ R_OUIRED FOR ELECTRONIC

THERMOSTATS

I[ TER CO_,IPONENT "¢VIRING

F-_-I

......... SE# #OT_ 4

AI TERNAT# NIR_ND EONF 16URATION

24 V'. '_ FIELD

----LINE /uiv'v'IS<INO

J I

r 1

ISOLATION RELAY

{HELD SUPPLIED}

SEE NOTE 4

ISOLATION RELAy

SEE NOTE 4

From Dwg. 21B341336 Rev. 2

24 V. / _> Y'i]R'ING

-- L INE .;,

h FACTO:{'{

,{]fffffffffffffff

TWINNING CONNECTION DIAGRAM

FOR TWINNING UX/DX-R FURNACES

2 STAGE HEAT/1 STAGE COOLING THERMOSTAT

OUTDOOR UNIT NO. 1 2 STAGE HEATING

(WITH TRANSFORMER) 1STAGE COOLING

SEE NOTE 3 THERMOSTAT

OUTDOOR UNIT NO. 1

(NO TRANSFORMER)

Fq Fq

• i

• "I

I _OTN EURNAC[S RUST B[ POWERED #RON

THE SAME HSV I£D O# CIRCUIT PANEl

R INSUR_ 24V FURNAC_ TRANSFORMERS AN_

IN PHASE PRIOR TO COMPLETING CONNECTIONS, CHECK VOLTAGE BETNEEN "R" TERMINALS OF EACH _URNACE /_ VOLTAGE IS GREATER THAN

JOY, REVERSE THE _L AN RD SECONDARY LEADS ON ON# 0# THE #URNAC[ TRANSfORMeRS

S iF OUTDOOR UNIT HAS A RAY TRANSFORM[R,

AN ISOLATION RELAF MUST BE _NSTALLED (FIELR SUPPLIEO USE PILOT DUTY REIAY ('RE'), SUCH AS RLYORYR ) SEE ALT CONNECTION

IF CURRENT EXCEEDS TNERNOGTAT CURRENT RATING, USE ISOLATION RELAYS {'RI') AS SNO_N (DO NOT CONNECT _ TO _)

ISOIATION REIAY NOT NEEDED _F THE THERMOSTAT

s?sj;? R

CONTACTS ARE RATED AT IRA OR ABOVE

CONNECTION MAY DE REQUIRED FOR ELECTRONIC

THE RNOS TATS

ISaAT_ON RELAY (F_ELDSUPPUEO)

SEE NOTE 4

r ,

FURNACE NO. 2

BLOWER OPERATION OF

UNIT NO 2 iSSYNCRONIZED

WITH UMT NO 1ViA SIGNA£5

FROM _IN CONNECTION

...... ' i

RI; L ;

R2; _1 :

--L-- ; I I I

INTER CO,,PC ENT ",/V]RINO

......... SEE NOTE 4

I I

-- LI[ E ._,/VIZ{IN("

From Dwg 21B341337 Rev, 2

ATERRATE _INlflG CORF_G_RATION

24 ,/. h> F ]Ek D

LINE ,/.J ',/'filING 24 '/. _ FACTO_{Y

28 18-CD19D8-15

Page 29

OUTDOOR UNiT NO. 2

(NO TRANSFORMER}

SEE NOTE 3

2STAGEHEATING

1STAGECOOLING

THERMOSTAT

TWINNING CONNECTION DIAGRAM

FOR TWINNING UX/DX-R FURNACES

2 STAGE HEAT / 2 STAGE COOLING THERMOSTAT

FURNACE NO. 1

FURNACE NO.2

BLOWEROPEraTIONOr

wl_ UNIT.Olvl_sle._Ls

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Installer's Guide

_OTE;

OUTDOOR UNiT NO 1

(NO TRANSFORMER)

SEE NOTE 5

CARBON MONOXIDE POISONING HAZARD

Failure to follow the installation instructions for the venting system being placed into operation could result in carbon

monoxide poisoning or death.

ISO_TIONRElY (FIELDSUPPLIED)

RI; _ 'J

tO ::

a2l_; :

From Dwg. 21 B341338 Rev. 2

ISO_TI_ nE_¥

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4 ¸ ;

m; ;

SOATO_ i #[iAr '¢0T _,_ F TU[ Trfl2_OSTRT

HITHTRANSFORMER

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I "

ACT_NAT_CO.NECTION

INTER CObIPONENT 'FT[R]NG

ALT!PNAT_ #HUt¢O (O_[ _PAT I_

24 /, I, FIE L D

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24 '/. ;% FA::T }RY--LINE " "A'[ _ IN G

OUTDOORUNIT

SEE NOTE 3

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ISO_TION RElY

ELECTRICAL CONNECTIONS

Make wiring connections to the unit as indicated on enclosed wiring diagram. As with all gas appliances using electrical

power, this furnace shall be connected into a permanently live electric circuit. It is recommended that furnace be

provided with a separate "circuit protection device" electric circuit. The furnace must be electrically grounded in accor-

dance with local codes or in the absence of local codes with the National Electrical Code, ANSI/NFPA 70 or CSA C22.1

Electrical Code, if an external electrical source is utilized.

The integrated furnace control is polarity sensitive.

The hot leg of the 120V power supply must be connected to the black power lead as indicated on the wiring diagram.

Provision for hooldng up an electronic air cleaner and or humidifier is provided on the integrated control.

Refer to the SERVICE FACTS literature and unit wiring diagram attached to furnace.

18-CD19D8-15 29

Page 30

Installer's Guide

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

MAIN MANUAL m

SHUT-O FF VALVE

GROUND

UNION

JOINT ._

MAIN MANUAL

SHUT-OFF VALVE

GROUND

UNION JOINT

DRIP

LEG

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

iii!iiiiii'i_iiiiliiliiliiliiliiliiliiliiliiliiliiliiliiliil/

DRIP _

LEG

UPFLOW MAY BE LEFT OR

RIGHT HAND GAS PIPING

AUTOMATIC GAS VALVE

WITH MANUAL SHUT-OFF

MAIN MANUAL

SHUT-OFF VALVE

GRO_

UNION JOINT !

HORIZONTAL FURNACE GAS PIPING MAY BE FROM EITHER SIDE

(Typical UPFLOW Furnace in horizontal configuration shown)

THE DOWNFLOW (VERTICAL) MAY BE INSTALLED

LEFT OR RIGHT SIDE GAS PIPING

MAIN MANUAL / GROUND UNION JOINT

VALVE DRIP

SHUT-OFF _

AIR

FLOW

AUTOMATIC GAS VALVE WITH

MANUAL SHUT-OFF

LEG

30 18-CD19D8-15

Page 31

Installer's Guide

GAS PIPING

The upflow/horizontal furnace is shipped standard for left side installation of gas piping. A knockout is provided on the right side for an alternate gas piping arrangement. See Figure

45. The installation of piping shall be in accordance with piping

codes and the regulations of the local gas company. Pipe joint compound must be resistant to the chemical reaction with liquefied petroleum gases.

Refer to piping Table 8, for delivery sizes. Connect gas supply to the unit, using a ground joint union and a manual shut-off valve as shown in Figures 44 & 45. National codes require a condensation drip leg to be installed ahead of the controls as shown in Figures 45 & 46.

Use a backup wrench on the gas valve when installing gas piping to prevent damage to the gas valve and manifold assembly.

The furnace and its individual shut-offvalve must be discon- nected from the gas supply piping system during any pressure

testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).

The furnace must be isolated from the gas supply piping by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test

pressures equal to or less than 1/2 psig (3.5 kPa).

NOTE: Maximum pressure to the gas valve for natural gas is 13.8"

W.C. Minimum pressure is 5.0" W.C. Maximum pressure to

the gas valve for propane is 13.8" W.C. Minimum pressure is 11.0" W.C.

All gas fittings must be checked for leaks using a soapy

solution before lighting the furnace. DO NOT CHECK

WITH AN OPEN FLAME!

TABLE 8 NATURAL GAS ONLY

TABLE OF CUBIC FEET PER HOUR OF GAS

FOR VARIOUS PIPE SIZES AND LENGTHS

PIPE LENGTH OF PIPE

SIZE 10 20 30 40 50 60 70

1/2 132 92 73 63 56 50 46

3/4 278 190 152 130 115 105 96

1 520 350 285 245 215 195 180

1-1/4 1050 730 590 520 440 400 370

This table is based on pressure drop of 0.3 inch W.C. and 0.6 SRGR. gas

TABLE 9 ORIFICE SIZES

INPUT

RATING

BTUH

60,000 80,000

100,000 120,000

NUMBER

BURNERS

3 4 5

MAIN BURNER ORIFICE

DRILL SIZE

NAT. GAS LP GAS

45 56 45 56

COMBUSTION AND INPUT CHECK (See also High Altitude Derate)

1. Make sure all gas appliances are off except the furnace.

2. Clock the gas meter with the furnace operating (deter- mine the dial rating of the meter) for one revolution.

3. Match the "See" column in the gas flow (in cfh) Table 10 with the time clocked.

4. Read the "Flow" column opposite the number of seconds clocked.

5. Use the following factors if necessary: For 1 Cu. Ft. Dial Gas Flow CFH =

Chart Flow Reading + 2

For 1/2 Cu Ft. Dial Gas Flow CFH =

Chart Flow Reading + 4

For 5 Cu. Ft. Dial Gas Flow CFH =

10X Chart Flow Reading + 4

PRESSURE WITH BURNER BOX REFERENCED

A CAUTION: Beturna,tubing,caps,an, orplugstooriginalpositionswhenpressurechecksare completed.

18-CD19D8-15 31

CORRECT METHOD OF CHECKING DIRECT VENT MANIFOLD

Separate the tube I

at the unit Tee and _'

reconnectwith a ,.-. II "_t

shortpiece of field _ II I I

supplied tube and T 11 I I

anotherTeewith /7 _ I ] the "U" Manometer /¢_/ /1

attached. /__ II

Besuretoreconneot I{ JJ

unit tubing to original -- _ \'\ _/ position after testing -- _k_

the manifold pressu re! ___.

Field supplied barb fitting | with manom eter tube is _IL

attached to the"OUTLET _ j PRESSURE TAP" on the

outlet side of the gas valve,

Page 32

Installer's Guide

6. Multiply the final figure by the heating value of the gas obtained from the utility company and compare to the nameplate rating. This must not exceed the name- plate rating.

7. Changes can be made by adjusting the manifold pressure (See Table 11), or changing orifices (orifice change may not always be required). To adjust the manifold pressure:

a. Turn off all electrical power to the system.

b. Attach a manifold pressure gauge to the outlet

pressure tap marked "OUT PRESS TAP" on White-Rodgers gas valve model 36E or boss marked "OUT P" on White-Rodgers gas valve model 36G. (See Figure 48 for White-Rodgers gas valve model 36E and Figure 49 for White-Rodgers gas valve model 36G). For the gas valve model 36E, measurements require removal of the plug and installation of a barbed fitting. Attach flexible tubing and a manometer to the barbed fitting. For the gas valve model 36G, do not remove the pressure tap test screw. Loosen the pressure tap test screw one turn and install flexible tubing and a manometer directly onto the outlet pressure boss.

c. The other side of the manifold pressure gauge must be

referenced to the burner box as shown in Figure 46.

d. Turn on system power and energize valve. e. For the White-Rodgers gas valve model 36E:

1. Adjust low fire by removing the low adjustment

seal screw (See Figure 48).

TABLE 10

GAS FLOW IN CUBIC FEET PER HOUR

2 CUBIC FOOT DIAL

SEC. FLOW SEC.

8 900 29 9 800 30

10 720 31

11 655 32

12 600 33 13 555 34 14 514 35 15 480 36 16 450 37 17 424 38 18 400 39 19 379 40

20 360 41

21 343 42

22 327 43 23 313 44 24 300 45 25 288 46 26 277 47 27 267 48 28 257 49

FLOW SEC. FLOW SEC. FLOW

248 50 144 82 88 240 51 141 84 86 232 52 138 86 84 225 53 136 88 82

218 54 133 90 80 212 55 131 92 78 206 56 129 94 76 200 57 126 96 75

195 58 124 98 73 189 59 122 100 72 185 60 120 104 69 180 62 116 108 67 176 64 112 112 64 172 66 109 116 62

167 68 106 120 60 164 70 103 124 58 160 72 100 128 56 157 74 97 132 54 153 76 95 136 53 150 78 92 140 51 147 80 90 144 50

TABLE 11

FINAL MANIFOLD

FUEL

NATURAL GAS

LP GAS

PRESSURE SETTINGS (inches w.c.)

2nd Stage Max. 1st Stage Max.

3.5" W.C. 1.7" W.C.

10.5" W.C. 6.0" W.C.

2. To increase outlet pressure, turn the 3/32" socket

set screw clockwise. To decrease outlet pressure, turn the set screw counterclockwise. Adjust regula- tor until pressure shown on manometer matches the pressure specified in Table 11.

3. Replace low adjustment seal screw and tighten securely.

4. Cycle the valve several times to verify regulator setting.

5. Adjust high fire by removing the high adjustment seal screw (See Figure 48).

6. To increase outlet pressure, turn the 3/32" socket set screw clockwise. To decrease outlet pressure, turn the set screw counterclockwise. The final

manifold pressure setting shall be as specified in Table 11 with an input of no more than nameplate

rating and no less than 93% of the nameplate rating, unless the unit is derated for high altitude.

7. Replace high adjustment seal screw and tighten securely.

8. Cycle the valve several times to verify regulator setting.

f. For the White-Rodgers gas valve model 36G:

HIGHALTITUDE DERATE

Input ratings (BTUH) of these furnaces are based on sea level operation and should not be changed at elevations up to

2,000 ft. If the installation is 2,000 ft. or above, the furnace input rate

(BTUH) shall be reduced 4% for each 1,000 ft. above sea level. The furnace input rate shall be checked by clocldng the gas

flow rate (CFH) and multiplying by the heating value obtained from the local utility supplier for the gas being

delivered at the installed altitude. Input rate changes can be made by adjusting the manifold pressure (min 3.0 - max

3.7 in. W.C. - Natural Gas) or changing orifices (orifice change may not always be required).

If the desired input rate cannot be achieved with a change in manifold pressure, then the orifices must be changed. LP

installations will require an orifice change.

IMPORTANT: Reinstall the propane orifices to the same depth as the orifices

supplied with the equipment.

Installation of this furnace at altitudes above 2,000 ft. (610m) shall be in accordance with the local codes, or in the absence of local codes, the National Fuel Gas Code, ANSI

Z223.1 / NFPA 54 or National Standard of' Canada, Natural Gas and Propane Installation Code, CSA 149.1. Installation of

this furnace at altitudes above 2,000 ft. (610m) shall be made in accordance with the listed high Altitude Conversion Kit

available with this furnace.

TABLE 12

PART NUMBERS FOR REPLACEMENT ORIFICES

DRILL

SIZE

44 45

46 47

48 49

PART

NUMBER

ORF00501

ORF00644 ORF00909

ORF00910 ORF01099 ORF00503

ORF00493

DRILL

SIZE

54 55

56 57

58 59

PART

NUMBER

ORF00555 ORF00693

ORF00907 ORF00908

ORF01338 ORF01339

32 18-CD19D8-15

Page 33

See Table 13 forhelp in selectingorificesiforificechange is required. Fu_'nace input rateand temperature riseshould be checked again afterchanging orificesto confirm the proper rate

forthe altitude.

The vent length table on page 16 shows the required vent lengths for installationsat various altitudes.An optional high altitudeidt isavailable for installationsabove 5000 feet Installationsabove 12,000 feet are not allowed).

TABLE 13

Orifice

Twist Drill

ALTITUDE ABOVE SEA LEVEL

Size If

Installed

and Orifice Required At Other Elevations

At Sea

Level

42 43 44 45 46 47

2000 3000 400G 5000 6000 700G 8000 9000 10000

42 43 43 43 44 44 45 46 47 44 44 44 45 45 46 47 47 48 45 45 45 46 47 47 48 48 50 46 47 47 47 48 48 49 49 50 47 47 47 48 48 49 49 50 51 48 48 49 49 49 50 50 51 52

54 54 55 55 55 55 55 56 56 56 55 55 55 55 56 56 56 56 56 57 56 56 56 57 57 57 58 59 59 60 57 58 59 59 60 60 61 62 63 63 58 59 60 60 61 62 62 63 63 64

From N_ional Fuel Gas Code-Table F-4

White-Rodgers 36E

2nd Stage (HI) Manifold Pressure

Adjustment

1st Stage (LO)

Gas Valve On / Off Toggle Switch

White-Rodgers36G 2nd Stage (HI) Manifold

Pressure Adjustment

Gas Valve On / Off Toggle Switch

1. Adjust low fire by removing the low adjustment regulator cover screw (See Figure 49).

2. To increase outlet pressure, turn the regulator adjust screw clockwise. To decrease outlet pressure, turn the regulator adjust screw counterclockwise. Adjust regulator until pressure shown on mano- meter matches the pressure specified in Table 11.

3. Replace and tighten the regulator cover screw

securely.

Manifold Pressure

Adjustment

1st Stage (LO) Manifold Pressure

Adjustment

Installer's Guide

ROTATE THE FRONT COVER AS SHOWN

INSERT THE TOP FLANGE OF THE FRONT COVER

UNDER THE LIP INSIDE

THE BOX

ALL SIDE FLANGES MUST

BE OUTSIDE OF THE BOX

ROTATE THE FRONT COVER INWARD MAKING

SURE THAT ALL SIDE

FLANGES ARE OUTSIDE OF THE BOX.

4. Cycle the valve several times to verify regulator setting.

5. Adjust high fire by removing the high adjustment

regulator cover screw (See Figure 49).

6. To increase outlet pressure, turn the regulator

adjust screw clockwise. To decrease outlet pressure, turn the regulator adjust screw counterclockwise. The final manifold pressure setting shall be as

specified in Table 11 with an input of no more than

nameplate rating and no less than 93% of the nameplate rating, unless the unit is derated for high altitude.

7. Replace high adjustment regulator cover screw and

tighten securely.

8. Cycle the valve several times to verify regulator setting.

g. Turn off all electrical power to the system.

h. Remove the manometer and flexible tubing. Remove

the barbed fitting and replace the plug or tighten the pressure test screw.

i. Turn on electrical power to the system and energize

valve.

j.Using a leakdetectionsolutionorsoap suds,checkfor

leaksatplugor pressurebossscrew.

NOTE:

The manifold pressure must be referenced to the burner

box. The burner box pressure tap equalizes the gas valve pressure regulator. Manifold pressure is checked by installing a tee (field supplied) in the tubing, between the tee coming from the burner box tube and the gas valve, in addition to the regular gas valve pressure tap on the outlet side of the gas valve. See Figure 47.

18-CD19D8-15 33

Page 34

Installer's Guide

EXPLOSION HAZARD! PROPANE GAS IS HEAVIER THAN AIR AND MAY COL- LECT IN ANY LOW AREAS OR CONFINED SPACES. IN

ADDITION, ODORANT FADE MAY MAKE THE GAS UNDETECTABLE EXCEPT WITH A WARNING DEVICE. IF

THE GAS FURNACE IS INSTALLED IN A BASEMENT, AN EXCAVATED AREA OR A CONFINED SPACE, IT IS STRONGLY RECOMMENDED TO CONTACT A GAS

SUPPLIER TO INSTALL A GAS DETECTING WARNING DEVICE IN CASE OF A GAS LEAK.

NOTE: The manufacturer of your furnace does NOT test any detectors and makes no representations regarding any brand or type of detector.

Replace and/or tighten all plugs removed or loosened when adjusting gas pressure. Leak check the fittings before placing the furnace into regular service. Failure to follow this warning could result in fire, explosion, or property damage.

Table 12 lists the main burner orifices used with the furnace. If a change of orifices is required to correct the furnace input

rating refer to Table 13.

REINSTALLATION OF THE BURNER BOX COVER

Figure 49 shows the correct way to reinstall the burner box cover if adjustment or replacement of the flame sensor, hot surface igniter, or main burner orifices have required re-

moval of the cover.

START-UP AND ADJUSTMENT

PRELIMINARY INSPECTIONS

Disconnect power to the unit before removing the blower door. Allow a minimum of 10 seconds for IFC power supply to drain to 0 volts. Failure to follow this warning could result in property damage, personal injury or death.

With gas and electrical power "OFF"

1. Duct connections are properly sealed

2. Filters are in place

3. Venting is properly assembled

4. Blower door is in place

Turn the main gas valve toggle switch (See Figures 48 & 49) within the unit to the "OFF" position. Turn the external gas valve to "ON". Purge the air from the gas lines. After purging, check all gas connections for leaks with a soapy solution --

DO NOT CHECK W1TH AN OPEN FLAME. Allow 5 min- utes for any gas that might have escaped to dissipate.

LP Gas being heavier than air may require forced ventilation. Turn the toggle switch on the gas valve in the unit to the "ON" position.

LIGHTING INSTRUCTIONS

DO NOT attempt to manually light the burner. Failure to follow this warning could result in property damage, personal injury or death.

Lighting instructions appear on each unit. Each installation must be checked out at the time of initial start up to insure proper operation of all components. Check out should include putting the unit through one complete cycle as outlined below.

Turn on the main electrical supply and set the thermostat above the indicated temperature. The ignitor will automati- cally heat, then the gas valve is energized to permit the flow of gas to the burners. After ignition and flame is established, the flame control module monitors the flame and supplies power to the gas valve until the thermostat is satisfied.

To shut off

For complete shutdown: Turn the gas cock knob on the main gas valve to the "OFF" position (See Figure 44). Disconnect the electrical supply to the unit.

Ifthis is done during the cold weather months, provisions must be taken to prevent freeze-up of all water pipes and

water receptacles.

Whenever your house is to be vacant, arrange to have someone inspect your house for proper temperature. This is very important during freezing weather. If for any reason your furnace should fail to operate dam- age could result, such as frozen water pipes.

SEQUENCE OF OPERATION Thermostat call for heat (2-stage thermostat)

Call for 1st stage only:

Wl thermostat contacts close signaling the control module to run its self-check routine. After the control module has

verified that the 1st stage pressure switch contacts are open and the limit switch(es) contacts are closed, the draft blower

will be energized. As the induced draft blower comes up to speed, the pressure

switch contacts will close and the ignitor warm up period will begin. The ignitor will heat for approx. 20 seconds, then the gas valve is energized in 1st stage to permit gas flow to the

burners. The flame sensor confirms that ignition has been achieved

within the 4 second ignition trial period. As the flame sensor confirms that ignition has been achieved,

the delay to fan ON period begins timing and after approx. 45 seconds the indoor blower motor will be energized at low speed and will continue to run during the heating cycle.

Call for 2nd stage after 1st stage:

W2 thermostat contacts close signaling a call for 2nd stage heat. After a 30 second delay, the induced draft blower will be energized on high speed and the 2nd stage pressure switch contacts will close. The gas valve is energized in 2nd stage and the indoor blower motor in high speed.

2nd stage satisfied, 1st stage still called: W2 thermostat contacts open signaling that 2nd stage heating requirements are satisfied.

The induced draft blower is reduced to low speed allowing the 2nd stage pressure switch contacts to open and the gas valve is reduced to 1st stage. The indoor blower motor is reduced to low speed.

1st stage satisfied: W1 thermostat contacts open signaling that 1st stage heating requirements are satisfied. The gas valve will close and the induced draft blower will be de-energized. The indoor blower motor will continue to run for the fan off period (Field selectable at 60, 100, 140 or 180 seconds), then will be de-energized by the control module.

34 18-CD19D8-15

Page 35

Installer's Guide

Thermostat call for heat (1-stage Thermostat)

W1/W2 (jumpered) thermostat contacts close signaling a call

for heat. 1st stage sequence of operation remains the same as above. 2nd stage heat will energize after the stage delay timer (field selectable at .5, 5, 10 or 15 minutes) has expired.

Thermostat satisfied:

W1/W2 (jumpered) contacts open signaling the control

module to close the gas valve. The induced draft blower is switched to low speed and de-energized after the post purge timer has expired. The indoor blower motor will continue to operate after the flames are extinguished and then is switched to low heat speed for the FAN-OFF period.

CONTROL AND SAFETY SWITCH ADJUSTMENTS LIMIT SWITCH CHECK OUT

The limit switch is a safety device designed to close the gas valve should the furnace become overheated. Since proper

operation of this switch is important to the safety of the unit, it must be checked out on initial start up by the installer.

To check for proper operation of the limit switches, set the thermostat to a temperature higher than the indicated temperature to bring on the gas valve. Restrict the airflow

by blocking the return air (disconnecting the indoor blower

may trip the inducer limit). When the furnace reaches the maximum outlet temperature as shown on the rating plate, the burners must shut off. If they do not shut off after a reasonable time and overheating is evident, a faulty limit switch is probable and the limit switch must be replaced.

After checking the operation of the limit control, be sure to

remove the paper or cardboard from the return air inlet. Refer to Service Facts for additional instructions.

NOTE TO INSTALLER

Review the following warnings with the owner. Review con- tents of USER'S INFORMATION MANUAL with the owner.

AIRFLOW ADJUSTMENT

Check inlet and outlet air temperatures to make sure they

iiiiiiiii;iiiiiiiiiiiiIi iiiiiiliiiiiiiiHii

iiii!

are within the ranges specified on the furnace rating name- plate. If the airflow needs to be increased or decreased, see the wiring diagram for information on changing the speed of

the blower motor.

ROOM AIR THERMOSTAT HEAT ANTICIPATOR ADJUSTMENT

Set the thermostat heat anticipator according to the current flow measured, or the settings found in the notes on the furnace wiring diagram (found in the SERVICE FACTS or inside the furnace casing).

INSTRUCTIONS TO THE OWNERS

In the event that electrical, fuel, or mechanical failures occur, the owner should immediately turn the gas supply off at the manual gas valve, located in the

burner compartment. Also turn off electrical power to

the furnace and contact the service agency designated

by your dealer.

BURNER BOX TEMPERATURE LIMIT DEVICE

All models are equipped with a manual reset temperature

limit located on the burner box. In case of excessive tempera- ture, the limit will open and cause the circuit to open which shuts off all flow of gas.

Disconnect power to the unit before removing the blower door. Allow a minimum of 10 seconds for IFC power supply

to drain to 0 volts. Failure to follow this warning could

result in property damage, personal injury or death.

This unit is equipped with a blower door switch which cuts power to the blower and gas valve causing shutdown when the door is removed. Operation with the door removed or ajar can permit the escape of dangerous fumes. All panels must be securely closed at all times for safe operation of the furnace.

INDOOR BLOWER TIMING

Heating: The integrated furnace control module controls the indoor blower. The blower start is fixed at 45 seconds after

ignition. The FAN-OFF period is field selectable by dip switches SW-2, #1 and #2 at 60, 100, 140, or 180 seconds. The factory setting is 100 seconds.

Wl-W2 stage delay (jumpered together) is field selectable by

dip switch SW-1, #1 and #2 at .5, 5, 10 or 15 minutes. The factory setting is 10 minutes. (See wiring diagram).

Cooling: The fan delay off period is factory set at 0 seconds. The option for 80 second delay off is field selectable by dip switch SW-2, #3 (See wiring diagram).

18-CD19D8-15 35

Page 36

Installer's Guide

ABNORMAL CONDITIONS

1. EXCESSIVE COMBUSTION PRESSURE (WIND IN EXCESS OF 40 MP.H.) VENT OR FLUE BLOCKAGE

On a call for heat, the variable speed draft inducer must first ramp up to speed and close the pressure switch before the ignition sequence is allowed to begin. If the pressure switch does not close, the motor will ramp up to maximum speed and continue to operate there for about

i minute.

After one minute the integrated furnace control will turn the motor off for about 30 seconds then back on in an

attempt to reestablish proper operation. This condition is indicative of a highly restricted or blocked inlet or outlet vent pipe or a failed pressure switch.

If pressure against induced draft blower outlet becomes excessive, the pressure switch will open. If the pressure switch is open for more than 3.5 seconds, the variable speed draft inducer will speed up and attempt to close the pressure switch. If the pressure switch is not closed within 12 seconds or if the maximum speed of the motor is reached, the draft inducer sends a fault signal to the integrated furnace control. If the unit is operating in second stage, an inducer fault will cause the furnace control to transition the system to first stage and it will operate there for 10 minutes before attempting to run again in second stage. If the unit is operating in first stage, an inducer fault will cause the furnace control to shut the system down and wait 30 seconds before attempting to reestablish operation in first stage.

2. LOSS OF FLAME If loss of flame occurs during a heating cycle, or flame is

not present at the sensor, the flame control module will close the gas valve. The flame control module will then recycle the ignition sequence, then if ignition is not achieved, it will shut offthe gas valve and lock out the system.

3. POWER FAILURE If there is a power failure during a heating cycle, the

system will restart the ignition sequence automatically when power is restored, if the thermostat still calls for

heat.

4. GAS SUPPLY FAILURE If loss of flame occurs during a heating cycle, the system

integrated control module will recycle the ignition sequence, then if ignition is not achieved, the integrated control module will shut offthe gas vNve and lock out the system.

5. INDUCED DRAFT BLOWER FAILURE Please refer to the variable speed draft inducer

troubleshooting manual for diagnostic assistance.

6. CONDENSATE DRAIN BLOCKAGE If the condensate drain is blocked, either by debris,

improper draining, or by freezing condensate, the pressure switch will sense the accumulation ofconden- sate in the furnace drain pan. The unit will not operate properly until the condensate drain has been cleared, and the condensate flows freely.

7. RESET AFTER LOCKOUT When the integrated control module has shut the system

down and gone into lockout, the system must be manu- ally reset before the unit will restart. The system can be reset by turning the system power off for more than

1 second, or by removing 24VAC from the control for more

than 1 second, or by removing the thermostat call for heat for more than 1 second but less than 20 seconds.

8. RESET AFTER BURNER BOX LIMIT SHUTDOWN If the furnace shuts down, one thing that can be checked

is the burner box temperature limit switch. It is located on the bottom of the burner box. The vent and combus-

tion air inlet terminations should be checked for block- age. If blockage exists, clear the problem and then the

reset button may be depressed. If there is no block- age of the terminations, the limit switch must be reset by a qualified servicer.

36 18-CD19D8-15

Page 37

FAULT CODE RECOVERY

On power up, last 4 faults, if any, will be flashed on the red LED. The newest fault detected will flash first and the oldest

last. There will be a 2 second delay between fault code flashes. Solid red LED error codes will not be displayed.

The Green LED will be on solid during last fault recovery.

At any other time the control is powered, the Green LED

indicator light will operate as shown in Table 14 and the red LED will flash LitePort data (one flash) every 20 seconds.

Fault Code Reset

The last 4 fault codes can be erased from memory by power- ing up the control with "G" energized and then applying "R" to the "WI" terminal 3 times within 6 seconds. The control

will acknowledge the reset by turning on the red LED for 2 seconds.

TABLE 14

INTEGRATED FURNACE CONTROL

GREEN "STATUS" LED FLASH CODES

Flashing Slow --- Normal - No call for Heat

Flashing Fast --- Normal - Call for Heat

Installer's Guide

Green Status LED

*UX / DX Integrated Furnace Control

INTEGRATED FURNACE CONTROL RED LED "ERROR" FLASH CODES

2 Flashes --- System Lockout (Retries or Recycles exceeded)

Draft Pressure Error- Possible problems:

3 Flashes ---

a) Venting problem b) Pressure switch problem c) Inducer problem

4 Flashes --- 5 Flashes ---

6 Flashes---

Open Temperature Limit Switch

Flame sensed when no flame should be present

115 volt AC power reversed, ignitor (Triac) fault, poor grounding or system voltage too low

7 Flashes ---

Gas valve circuit error

8 Flashes --- Low flame sense 9 Flashes --- Open Inducer Limit switch

10 Flashes --- Inducer communication error Solid --- Internal GV error or Low TH voltage

Solid Red w/Solid Green "STATUS" LED

Continuous Reset caused by a blown fuse or internal error.

18-CD19D8-15 37

Page 38

Trane

6200 Troup Highway

Tyler, TX 75707

For more information contact Since the manufacturer has a policy of continuous product and product data improvement, it reserves the right to your local dealer (distributor) change design and specifications without notice.

03/08

Trane UX2B060A9362A, UX2D120A9602A, DX2B060A9362A, DX2B080A9422A, DX2C100A9482A Installer's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual